Polymer-Inorganic Composite And Hybrid Material And It's Application To Automobile

Energy sources and environment problem will be present human society with huge challenges. To meet the needs of modern society,automobile is moving to the light weight, safety, energy-saving, and environmental protection direction. The development and application of the new materials is one of the leading ways of achieving the light weight automobile.In this dissertation,titania containing organic/inorganic hybrid films and polypropylene/clay nanocomposite are prepared and their properties are investigated and, SMC(sheet molding compound) used as oil pan is developed.In chapter 2: Through discussing the categories of the films and film plating methods, which help to improve the performance of the plastic surface, we ultimately select so-gel method. With this method, a series of titania containing organic/inorganic hybrid films with high nD and performance are prepared by co-hydrolysis of silane coupling agent (3-Glycidyloxypropyl) trimethoxysilane (KH-560) and titanium butoxide [Ti(OBu)4] through controlling the experimental conditions without using any stabilizer. In the course of film study, titanate hydrolysis rate control method, sol system stability and its factors, and film curing process are discussed, and meanwhile, microstructure, optical, mechanical and thermal properties of hybrid films were characterized by using different methods. FTIR indicates that the different components have been successfully combined to hybrids by covalent bonds. TGA indicates these hybrid films have good thermal durability. AFM and TEM indicate the films have smooth surface and the titania nano-phase (<3 nm) were well dispersed in all the films without aggregations even in the film with high titania content. UV-vis transmission spectra indicate the hybrid films have high transparency of above 90% in the range of visible light, which is in accordance with AFM and TEM results. In addition, the refractive index of the hybrid films could be adjusted linearly from 1.5 to 1.7 by altering titania content. The pencil hardness of the films is 4-5H both before and after aging and all the films have good adhesion performance to substrate materials. The hybrid films have potential applications in resin lenses, car lights lamp and the wear-resistant protective coating on the surface of CD-ROM.In chapter 3 :Organo-montmorillonites with hydroxyl, epoxy and non-polar groups are prepared respectively. They are used to prepare PP/clay nanocomposites with MAH-g-PP as compatilizer. XRD, TEM, DSC TGA are employed to investigate the structure of the organo-montmorillonites. The effect of various organo-montmorillonites on the structure and properties of PP/clay nanocomposites are also studied. The results show that organo-montmorillonite with polar group has strong affinity with MAH-g-PP, which benefits the intercalation of exfoliation and clay, therefore the mechanical properties of the nonocomposites are enhanced more substantially. On the basis of the theoretical study, we adjusted and determined the formulation of the nanocomposite for the car heater shell material. The research on the performance of the PP / clay nanocomposite and the shaping process of the car heaters shell are conducted. The results show that the car heater shell that adopts this new polypropylene / clay nanocomposite material pass through all the tests and standards required by the car heater. Since less mineral filler is required compared to the traditional talc reinforced polypropylene, this material is of advantage to the realization of lightweight auto parts, at the same time, it satisfies the regulation on the recyclability of the automobile materials.In chapter 4: After studying and evaluating of SMC composite properties we finally fixed the data of SMC composite used for engine oil pan. On the basis of the properties of SMC composite, we designed a new kind of engine oil pan. We forecasted the impact trend of the radiated noise caused by the new SMC oil pan structure by using the Hypermesh/Ahcv,Patran/MES,Nastran/ME and Sysnoise/LMS software. Through the test of SMC oil pan producing technique, we developed a kind of SMC oil pan part. Furthermore, we did several experiments, including head-resistant, cold-resistant, and road-test, nosis comparing of road-test between SMC oil pan and metal oil pan. The experimental results show that: 1)this new SMC oil pan had passed the road tests under standard road-test, tropic and frigid zone condition, which proved that the SMC oil pan can meet the use requirement of truck engines. 2) Compared with metal oil pan, assembling the SMC oil pan can reduce 0.4dB– 0.5dB noise out of truck. 3) Economical consideration: a) Comparing to the metal oil pan, the SMC oil pan can reduce weight about 50%. b) Comparing to the two layers metal oil pan or cast aluminium oil pan, the cost of the SMC oil pan is lower more than 25%. c) The SMC oil pan can meet the requirement of producing the oil pan with complex structure. Summing up the studies and experiments, we can conclude that SMC composite with high-performance, as its preponderance in achieving the mass losing, noise reducing and so on, is becoming the preferred materials for the auto functional parts.