WO2018124354A1 - Method for fabricating fiber-reinforced plastic composite material covered with sheet metal skins, and composite material component for lightweight structure fabricated by same - Google Patents

Abstract

The present invention relates to a method for fabricating a fiber-reinforced plastic composite material covered with sheet metal skins, the method comprising: a sheet metal skin pre-stamping step for stamping two sheet metals, thereby fabricating an upper sheet metal skin and a lower sheet metal skin; a pressing process preparation step for making preparations by mounting the upper sheet metal skin and the lower sheet metal skin on a press machine and positioning, between the upper sheet metal skin and the lower sheet metal skin, an inner material which is a thermosetting resin material having a reinforcement fiber mixed therein; a sheet metal skin pre-heating step for heating the upper sheet metal skin or the lower sheet metal skin; and a pressing process for press molding the thermosetting resin having a reinforcement fiber mixed therein, which is interposed between the upper sheet metal skin and the lower sheet metal skin, wherein, before or after the upper sheet metal skin and the lower sheet metal skin are mounted on the press machine, a thermosetting adhesive is applied on the lower surface of the upper sheet metal skin and the upper surface of the lower sheet metal skin, and in the pressing process, the thermosetting adhesive applied on the lower surface of the upper sheet metal skin and the upper surface of the lower sheet metal skin is cured and adhered at the same time as the thermosetting resin having a reinforcement fiber mixed therein is molded and cured.

Description

Manufacturing method of fiber-reinforced plastic composite material covered with metal plate skin and composite part for lightweight structure manufactured accordingly

The present invention relates to a method for manufacturing a composite material applied to a structure such as a vehicle body, and more particularly, to a method for manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin.

In general, structures such as automobile bodies are required to have both structural strength and rigidity to maintain their shape and to be molded into complex shapes. In consideration of such structural strength and formability, a structure in which a metal plate is pressed is widely used, but various materials are being researched because it is difficult to satisfy all the various characteristics required for the structure.

In the case of the polymer resin having excellent molding processability, it is common to not have the strength and rigidity of the structure, and in the case of the polymer resin composite material having the strength and rigidity as the structure, it is very expensive and is used only in special cases.

In addition, research on various composite materials has been conducted, but there are few materials satisfying strength, rigidity, and formability as structures. In particular, the sandwich-type composite material in which different materials are inserted between two materials among the composite materials has strengths to apply all the characteristics of various materials, but there are many problems in formability depending on the materials used. The field of application is very limited.

Prior Art Documents Republic of Korea Patent Publication 10-2014-0094050

SUMMARY OF THE INVENTION The present invention has been made in an effort to provide a novel method for manufacturing a fiber reinforced plastic composite material covered with a sheet metal skin and a composite part for a lightweight structure manufactured accordingly.

Method for producing a fiber-reinforced plastic composite material covered with a metal sheet skin according to the present invention for achieving the above object, metal sheet skin pre-stamping to manufacture the upper metal plate skin and the lower metal plate skin by stamping and molding two pieces of metal plate step; A press for installing the upper metal plate skin and the lower metal plate skin on a press equipment and placing a thermosetting resin material mixed with reinforcing fibers as an inner material between the upper metal plate skin and the lower metal plate skin. Process preparation step; A metal plate skin preheating step of heating the upper metal plate skin or the lower metal plate skin; And a press process for press molding a thermosetting resin mixed with reinforcing fibers disposed between the upper metal plate skin and the lower metal plate skin, wherein the upper metal plate skin and the lower metal plate skin are pressed into a press equipment. Before or after installation, a thermosetting adhesive is applied to the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin, and the upper metal plate material is formed while the thermosetting resin mixed with the reinforcing fiber is molded and cured in the pressing process. It is characterized in that the thermosetting adhesive applied to the lower surface of the skin and the upper surface of the lower metal plate skin is cured and bonded.

In the press process preparation step, the upper metal plate skin is attached to the upper frame of the press equipment, the lower metal plate skin is attached to the lower frame of the press equipment, and the upper metal plate skin is vacuum-adsorbed to the upper frame. It is preferable to attach.

The preheating step is preferably performed by heating the upper frame or the lower frame, it is preferably carried out by heating the upper frame and the lower frame at the same time.

As a thermosetting resin mixed with reinforcing fibers, it is preferable to use an SMC material, and in the press process preparation step, the SMC sheet may be placed on the surface of the lower metal plate skin coated with a thermosetting adhesive. At this time, it is preferable to divide the SMC sheet into a plurality of pieces to be spaced apart from each other.

 The material of the upper metal plate skin and the lower metal plate skin may be selected from materials such as aluminum, mild steel, high tensile steel (HSS), stainless steel (SUS), titanium and magnesium. At this time, the material of the upper metal plate skin and the lower metal plate skin may be configured differently.

In the method of manufacturing the fiber-reinforced plastic composite material covered with the metal sheet skin of the present invention, by molding two sheets of metal sheet skins first, and then inserting and bonding SMC therebetween, it is difficult to change the shape once cured. SMC has the flexibility of design to fabricate composite materials inserted into metal sheet skin into various shapes including curved surface. At the same time, it shows high productivity to produce fiber-reinforced plastic composites covered with metal sheet skin at low cost, and also has the effect of manufacturing large-area products.

The composite material part for a light weight structure according to another aspect of the present invention is a composite material part suitable for a structure that supports a load and maintains its appearance, and is manufactured by the above-described method, and the two metal sheet materials manufactured by molding a metal sheet in advance. skin; And an inner material of a thermosetting resin material interposed between the metal sheet skins and reinforcing fibers bonded by a thermosetting adhesive applied to each of the inner surfaces of the two sheet metal skins. The metal sheet skins are molded into a shape of an inner surface facing each other by a press process using metal sheet skins as a mold, and are bonded to the metal sheet skins by the thermosetting adhesive.

At this time, it is preferable that the internal material of the composite component part for the structure is SMC material, and the thickness of the internal material is preferably in the range of 60 to 80% of the total thickness of the composite material for the structure.

The material of the metal sheet skin constituting the composite material part for the structure may be aluminum, mild steel, high tensile strength steel (HSS), stainless steel (SUS), titanium, magnesium, or the like.

In addition, it is also possible to configure different materials for each of the two sheet metal skins constituting the composite component part for the structure.

It is preferable that the composite material part for structures of this invention is an automobile body.

The composite component part for a structure using the fiber-reinforced plastic composite material covered with the metal sheet skin of the present invention can additionally obtain the characteristics of the weighted and inserted internal materials while maintaining the advantages of the metal material structure. Specifically, in addition to the characteristics of the metal plate can exhibit the ability to block and absorb vibration and noise, as a result there is an effect that the specific strength and specific rigidity of the structure is further improved.

Furthermore, the composite component part for a structure of this invention is comprised by the metal plate skin which is a metal material on both surfaces, and is excellent in the adhesiveness with another metal part.

The method of manufacturing the fiber-reinforced plastic composite material covered with the metal sheet skin of the present invention configured as described above is made by stamping molding two metal sheet skins first, and then inserting and bonding the SMC therebetween, so as to cure once The SMC, which is difficult to change its shape, has the flexibility of designing the composite material inserted into the sheet metal skin into various shapes including curved surfaces. At the same time, it shows high productivity to produce fiber-reinforced plastic composites covered with metal sheet skin at low cost, and also has the effect of manufacturing large-area products.

In addition, the composite component part of the structure of the present invention can additionally obtain the characteristics of the weight and the internal material inserted while maintaining the advantages of the metal material structure. In particular, in addition to the characteristics of the metal plate can exhibit the ability to block and absorb vibration and noise, as a result there is an effect that the specific strength and specific rigidity of the composite composite component for the structure is further improved.

Furthermore, the composite component part for a structure of this invention is comprised by the metal plate skin which is a metal material on both surfaces, and is excellent in the adhesiveness with another metal part.

1 is a flow chart showing a method of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin according to an embodiment of the present invention.

2 is a view for explaining the pressing process preparation step for applying the method of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin according to the present embodiment.

3 is a view showing a pressing process preparation step during the manufacturing process of the fiber-reinforced plastic composite material covered with a metal sheet skin according to the present embodiment.

4 is a view showing a pressing process in the process of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin according to this embodiment.

Figure 5 shows the results of manufacturing the fiber-reinforced plastic composite material covered with a metal sheet skin according to this embodiment.

[Description of the code]

110: upper frame

120: lower frame

210: upper metal plate skin

220: lower metal plate skin

300: SMC sheet

310: internal material

With reference to the accompanying drawings will be described embodiments of the present invention;

1 is a flow chart showing a method of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin according to an embodiment of the present invention.

The method of manufacturing a fiber reinforced plastic composite material covered with the metal sheet skin of the present invention includes a metal sheet skin pre-stamping step, a press process preparation step, a metal sheet skin preheating step, and a press process step, and each of the specific steps will be described below. Take a look.

First, the manufacturing method of the present embodiment performs the pre-stamping to manufacture the upper metal plate skin and the lower metal plate skin by stamping molding the metal plate.

The stamping process can form irregularities on the surface in addition to molding the overall shape such as forming a curved surface on the metal sheet. It is common to form a curved surface in the case of a composite material using fiber-reinforced plastic and a metal material at the same time. However, the present invention is very easy to form a curved surface because the metal sheet is stamped and molded in advance.

At this time, the material of the metal plate may be used in a variety of high strength aluminum, mild steel, high-tensile steel (HSS), stainless steel (SUS), titanium, magnesium, and the like.

In addition, the upper metal plate skin and the lower metal plate skin are not limited to the same material, and when the upper metal plate skin becomes the outer surface and the lower metal plate skin becomes the inner surface, the upper metal plate skin has excellent anti-rust properties so as to be suitable for the outer surface. The metal material is selected, and the lower metal plate skin may select a metal material having excellent impact resistance to fit the inner surface, and vice versa. In addition, the shape to be molded is not particularly limited because it is a metal material, and any shape can be formed as long as the shape can be formed from a metal material.

Furthermore, the shape of the upper metal plate skin and the lower metal plate skin are not exactly the same, and the upper surface of the upper metal plate skin and the lower surface of the lower metal plate skin are exposed to the outside, respectively. This can be formed. At this time, the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin is preferably a shape corresponding to each other since the inner material is bonded portion, but is not essential. According to the manufacturing method of the present invention, even if the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin do not completely correspond to each other, the internal material is completely filled therebetween.

Next, the molded upper metal plate skin and the lower metal plate skin are installed in a press equipment, and a thermosetting resin material mixed with reinforcing fibers to be used as an internal material is placed to prepare a pressing process.

At this time, since the upper metal plate skin and the lower metal plate skin has already been stamped molding, the press equipment of the present invention is not intended to mold the upper metal plate skin and the lower metal plate skin. Specifically, the thermosetting resin material in which the reinforcing fibers interposed between the upper metal plate skin and the lower metal plate skin is mixed is molded as an inner material according to the shape of the upper metal plate skin and the lower metal plate skin, and the inner material is formed of the upper metal. Equipment for adhering to plate skin and lower metal plate skin. Therefore, the press pressure and heating temperature range of the press equipment are determined according to this purpose, and it is not necessary to reach the press pressure and heating temperature in the range necessary for forming the metal sheet.

In addition, although the upper frame and the lower frame of the press equipment do not function as a mold for forming the upper metal sheet skin and the lower metal sheet skin, the shape of the upper surface of the upper metal sheet skin and the lower surface of the lower metal sheet skin on which the forming is performed is not. It is desirable to match as closely as possible. As the upper surface of the upper frame and the upper surface of the lower frame coincide with the shape of the upper surface of the upper metal plate skin and the lower surface of the lower metal plate skin on which the molding is performed, pressure is applied evenly to the entire surface of the upper metal plate skin and the lower metal plate skin. Molding of the inner material is smoothly performed, and the inner material and the adhesive can be uniformly cured as a whole by keeping the temperature of the entire surface of the upper metal plate skin and the lower metal plate skin constant.

When the shape of the upper surface of the upper metal plate skin on which the molding of the press equipment is performed coincides with the shape of the lower surface of the upper frame, it is possible to attach the upper metal plate skin to the upper frame in a vacuum manner.

Meanwhile, before or after the upper metal plate skin and the lower metal plate skin are installed in the press equipment, a thermosetting adhesive is applied to the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin.

The thermosetting resin material mixed with the reinforcing fibers used as the inner material is placed on the upper surface of the lower metal plate skin coated with the thermosetting adhesive. At this time, the thermosetting resin material in which the reinforcing fibers are mixed is dispersed by reinforcing glass fibers or carbon fibers, and particularly, SMC (Sheet Molding Compound) is suitable.

SMC processed into a sheet form by dispersing and impregnating fibers such as glass fiber or carbon fiber in a viscous viscous resin, such as dough or clay, is often used in a molding process by pressing. The present invention uses the upper metal plate skin and the lower metal plate skin instead of the mold used in the press working of the SMC, thereby forming the SMC to match the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin, and at the same time, the upper metal plate material The skin and the lower metal plate skin and the SMC is bonded to the fiber-reinforced plastic composite material covered with the metal plate skin is inserted into the SMC as an internal material.

2 is a view for explaining a press process preparation step for applying a method of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin according to the present embodiment, Figure 3 is a fiber covered with a metal plate skin according to this embodiment A diagram showing the press process preparation step during the manufacturing process of the reinforced plastic composite material.

As shown, the lower metal plate skin 220 is disposed on the lower frame 120 of the press equipment, the upper frame 110 has a shape corresponding to the upper metal plate skin 210. In the preparation step, as shown in Figure 3, the upper metal plate skin 210 is placed in close contact with the upper mold 110 by the suction force by the vacuum.

Although not shown in the drawings, a thermosetting adhesive is applied to the lower surface of the upper metal plate skin 210 and an upper surface of the lower metal plate skin 220, and the SMC sheet 300 is divided into three pieces and a lower portion of the thermosetting adhesive is applied. It is positioned on the surface of the metal plate skin 220.

Since the SMC itself is not a hardened state, it is also possible to carry out the pressing process in a state in which one SMC sheet, which is one lumped state, is placed on the upper surface of the lower metal plate skin to which the thermosetting adhesive is applied. However, even when the SMC sheet 300 cut to the appropriate size, as shown in Figure 3 is properly dispersed and placed on the upper surface of the lower metal plate skin coated with the thermosetting adhesive, the SMC sheet pieces by the upper pressing Spreading between the metal plate skin and the lower metal plate skin can finally be in close contact with each other to form a single inner material, in this way it is possible to adjust the thickness of the inner material thin. Of course, by adjusting the distance that the upper frame is pressed in the state where one SMC sheet is placed, the thickness of the inner material is adjusted in such a way that the extra SMC escapes between the upper metal plate skin and the lower metal plate skin. However, if the waste of SMC is severe and the metal plate skins have a complicated structure, it may be difficult to produce the desired thickness because the inner SMC is not discharged to the outside.

And prior to performing the press process, the upper and lower frames of the press equipment are heated to preheat the upper and lower sheet metal skins to temperatures suitable for shaping and curing the SMC and curing the thermoset adhesive.

At this time, it is also possible to heat only one of the upper frame and the lower frame, heating both the upper frame and the lower frame is advantageous for the molding of the SMC and curing of the thermosetting adhesive. In the case of SMC, heating to a temperature of 165 DEG C or higher is common, but an appropriate temperature is selected according to the specific type of SMC.

Finally, a press process is performed to form the SMC, which is an internal material, between the upper metal plate skin and the lower metal plate skin so as to be cured at the same time. At this time, by selecting the thermosetting adhesive applied to the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin according to the molding and curing temperature of the internal material, in the process of forming and curing the SMC through the press process in this embodiment In addition, the curing of the thermosetting adhesive is performed so that the SMC constituting the inner material is bonded to the upper metal plate skin and the lower metal plate skin.

Figure 4 is a view showing a pressing process in the process of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin according to this embodiment, Figure 5 is a fiber-reinforced plastic covered with a metal plate skin according to this embodiment The result of manufacturing a composite material is shown.

As shown, when the upper metal plate skin 210 is attached to the upper frame 110 is moved downward to apply pressure to the SMC sheet 300, the upper metal plate skin 210 and the lower metal heated through the preheating process As the SMC sheet 300 spreads between the plate skins 220, the SMC sheet 300 is molded according to the shape of the lower surface of the upper metal plate skin 210 and the upper surface of the lower metal plate skin 220.

Finally, the SMC sheets are bonded to each other between the upper metal plate skin 210 and the lower metal plate skin 220, and an internal material 310 is inserted between the upper metal plate skin 210 and the lower metal plate skin 220. Fiber-reinforced plastic composites covered with sheet metal skins are produced.

On the other hand, in the case of the fiber-reinforced plastic composite material covered with the metal plate skin manufactured, in order to be applied as a structure, the thickness of the inner material 310 ranges from 60 to 80% of the total thickness of the fiber-reinforced plastic composite material covered with the metal plate skin. Is preferably. If it is thicker than this range, there is a problem that the properties of the internal material 310 are so strengthened that the rigidity and strength as a structure by the metal plate skins 210 and 220 are not obtained. There is a disadvantage that can not be exhibited.

The method for producing a fiber-reinforced plastic composite material covered with the metal sheet skin of the present invention described above is produced by stamping molding two metal sheet skins first, and then insert molding and adhering SMC therebetween. SMC, which is difficult to change, has the design flexibility to manufacture composite materials embedded in metal sheet skins in various shapes including curved surfaces. At the same time, it shows high productivity to produce fiber-reinforced plastic composites covered with metal sheet skin at low cost, and also has the effect of manufacturing large-area products.

In addition, the composite component part for a structure manufactured by the manufacturing method of the present invention can additionally obtain the characteristics of the inserted internal material while being lightweight while maintaining the advantages of the metal material structure. In particular, in addition to the characteristics of the metal plate can exhibit the ability to block and absorb vibration and noise, as a result there is an effect that the specific strength and specific rigidity of the composite composite component for the structure is further improved.

Furthermore, the composite component part for a structure manufactured by the manufacturing method of this invention is comprised by the metal plate skin which is a metal material on both surfaces, and is excellent in the bonding property with another metal part.

While the present invention has been described through the preferred embodiments, the above-described embodiments are merely illustrative of the technical idea of the present invention, and various changes may be made without departing from the technical idea of the present invention. Those of ordinary skill will understand. Therefore, the protection scope of the present invention should be interpreted not by the specific embodiments, but by the matters described in the claims, and all technical ideas within the equivalent scope should be interpreted as being included in the scope of the present invention.

Claims (14)

A metal sheet skin pre-stamping step of stamping and molding two sheet metal sheets to produce an upper metal sheet skin and a lower metal sheet skin; A press for installing the upper metal plate skin and the lower metal plate skin on a press equipment and placing a thermosetting resin material mixed with reinforcing fibers as an inner material between the upper metal plate skin and the lower metal plate skin. Process preparation step; A metal plate skin preheating step of heating the upper metal plate skin or the lower metal plate skin; And And a press process for press molding a thermosetting resin mixed with reinforcing fibers disposed between the upper metal plate skin and the lower metal plate skin. Before or after installing the upper metal plate skin and the lower metal plate skin to the press equipment, a thermosetting adhesive is applied to the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin, In the pressing process, the thermosetting resin mixed with the reinforcing fibers is molded and cured, and at the same time, the thermosetting adhesive applied to the lower surface of the upper metal plate skin and the upper surface of the lower metal plate skin is cured and bonded. Method of manufacturing fiber reinforced plastic composites covered with water. The method according to claim 1, In the press process preparation step, The upper sheet metal skin is attached to the upper frame of the press equipment is installed, the lower sheet metal skin is attached to the lower frame of the press equipment, The upper metal plate skin is a method of manufacturing a fiber-reinforced plastic composite material covered with a metal plate skin, characterized in that attached to the upper frame by a vacuum adsorption method. The method according to claim 2, The preheating step is a method of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin, characterized in that is performed by heating the upper frame or the lower frame. The method according to claim 1, The method of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin, characterized in that the thermosetting resin mixed with the reinforcing fiber is SMC material. The method according to claim 4, In the press process preparation step, A method for producing a fiber-reinforced plastic composite material covered with a metal sheet skin, wherein the SMC sheet is placed on a surface of a lower metal sheet skin coated with a thermosetting adhesive. The method according to claim 5, In the press process preparation step, The method of producing a fiber-reinforced plastic composite material covered with a metal sheet skin, characterized in that the SMC sheet is divided into a plurality of pieces to be spaced apart from each other. The method according to claim 1, The material of the upper metal plate skin and the lower metal plate skin is selected from aluminum, mild steel, high tensile steel (HSS), stainless steel (SUS), titanium and magnesium of the fiber-reinforced plastic composite material covered with a metal plate skin Manufacturing method. The method according to claim 1, The method of manufacturing a fiber-reinforced plastic composite material covered with a metal sheet skin, characterized in that the material of the upper metal plate skin and the lower metal plate skin is different. A structural part composed of a fiber reinforced plastic composite material covered with a metal sheet skin manufactured by the method of manufacturing a composite material of claim 1, Two metal sheet skins prepared by stamping molding a metal sheet in advance; And It is located between the metal plate skins, and consists of a thermosetting resin material of the internal reinforcing fibers bonded by a thermosetting adhesive applied to each of the inner surface facing the two sheet metal skins, The inner material is molded into the shape of the inner surface facing the two sheet metal skins by a press process using the metal sheet skins as a mold and at the same time adhered to the metal sheet skin by the thermosetting adhesive. Composite parts. The method according to claim 9, The composite material component for light weight structure, characterized in that the internal material is SMC material. The method according to claim 9, The composite material component for light weight structure, characterized in that the thickness of the internal material ranges from 60 to 80% of the total thickness of the composite material. The method according to claim 9, The material of the metal plate skin, the composite material for lightweight structures, characterized in that selected from aluminum, mild steel, high tensile strength steel (HSS), stainless steel (SUS), titanium and magnesium. The method according to claim 9, The composite material component for light weight structure, characterized in that the material of each of the two sheet metal skins are different. The method according to claim 9, The composite material component for light weight structure, characterized in that the composite material part for a lightweight structure is an automobile body.

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