Platformization front longitudinal beam rear reinforcing structure of new energy automobile and mounting method

Abstract

The invention discloses a new energy automobile platform front longitudinal beam rear reinforcing structure and an installation method. The new energy automobile platform front longitudinal beam rear reinforcing structure comprises a front longitudinal beam body, a front longitudinal beam cover plate, a front longitudinal beam reinforcing plate assembly and a front longitudinal beam structural rubber block. The front longitudinal beam body is connected with the front longitudinal beam cover plate, a cavity structure is formed in the front longitudinal beam body, and the front longitudinal beam reinforcing plate assembly and the front longitudinal beam structural rubber block are arranged in the cavity structure; the front longitudinal beam reinforcing plate assembly comprises a front longitudinal beam reinforcing plate, a front longitudinal beam supporting plate, a front longitudinal beam front reinforcing plate and a front longitudinal beam rear reinforcing plate. The front longitudinal beam structural rubber block comprises a glass fiber nylon framework and an epoxy resin foaming layer wrapping the framework. According to the front longitudinal beam, the safety problem caused by thermal runaway due to the fact that the rear portion of the front longitudinal beam is bent and a battery pack is extruded in the process of front collision or offset collision of a new energy automobile can be solved; meanwhile, the problems that in the prior art, a front longitudinal beam assembly is high in cost, multi-part production management is complex, and platformization is difficult are solved.

Description

Technical Field

[0001] This invention relates to the field of safety protection technology for new energy vehicles, specifically to a platform-based front longitudinal beam rear reinforcement structure and its installation method for new energy vehicles. Background Technology

[0002] The front longitudinal beam, located in the critical load-bearing area of ​​the front compartment of a car, is a major structural component of the front of the vehicle's frame. It directly connects the front bumper and the passenger compartment and bears the primary responsibility for transmitting impact forces during a collision. The front longitudinal beam performs two main functions in a collision: first, it absorbs and disperses collision energy, reducing the impact on the passenger compartment through crushing deformation; second, it prevents excessive intrusion into the front compartment, thus protecting the battery pack from compression and preventing thermal runaway. The increased weight of new energy vehicles places higher energy absorption demands on the front longitudinal beam, which traditional steel longitudinal beams struggle to meet, easily leading to crushing failure. In frontal or offset collisions of new energy vehicles, the rear part of the front longitudinal beam (i.e., the area closest to the passenger compartment and battery pack) is prone to bending deformation. This is because the 15-30% increase in vehicle weight amplifies the inertial forces during a collision, and the rear of traditional longitudinal beams lacks sufficient rigidity to effectively resist deformation. Once the rear part bends, the intrusion into the front compartment increases significantly, causing the battery pack to be compressed and triggering the risk of thermal runaway (such as a fire).

[0003] Existing technologies primarily strengthen the front longitudinal beams through material selection and structural design. In terms of materials, high-strength materials are mainly used to improve impact resistance, such as a hybrid approach using aluminum alloys or high-strength steel, enhancing the beam's stiffness and energy absorption capacity. In terms of structural design, multi-path force transmission is introduced to disperse collision forces. However, existing solutions have the following problems: using aluminum alloys or aluminum profiles, combined with multiple rear components, results in high material costs, a large number of parts, and a complex production and assembly process, increasing management difficulty and quality control risks. While aluminum profiles are lightweight, hybrid material solutions may increase overall weight, and component welds are prone to cracking under high impact, failing to completely solve the rear bending problem. Furthermore, the complex structure is not conducive to coating and corrosion protection, affecting long-term reliability. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a platform-based front longitudinal beam rear reinforcement structure and installation method for new energy vehicles. This can solve the safety problems caused by the large amount of front compartment immersion due to bending of the rear of the front longitudinal beam and thermal runaway caused by battery pack compression during frontal or offset collisions of new energy vehicles. At the same time, it solves the problems of high cost of the front longitudinal beam assembly, complex production management of multiple parts, and difficulty in platformization in the prior art.

[0005] The technical solution of the present invention is as follows: In a first aspect of the present invention, a platform-based front longitudinal beam rear reinforcement structure for new energy vehicles is provided, including a front longitudinal beam body, a front longitudinal beam cover plate, a front longitudinal beam reinforcement plate assembly, and a front longitudinal beam structural adhesive block. The front longitudinal beam body and the front longitudinal beam cover plate are connected to form a cavity structure. The front longitudinal beam reinforcing plate assembly and the front longitudinal beam structural adhesive block are disposed within the cavity structure. The front longitudinal beam reinforcing plate assembly includes a front longitudinal beam reinforcing plate, a front longitudinal beam support plate, a front reinforcing plate, and a rear reinforcing plate. The front longitudinal beam support plate and the front reinforcing plate are both connected to the front longitudinal beam reinforcing plate. The front longitudinal beam reinforcing plate is connected to the inner surface of the front longitudinal beam body. The rear reinforcing plate is connected to the rear end of the front longitudinal beam cover plate. The front longitudinal beam structural adhesive block includes a fiberglass nylon skeleton and an epoxy resin foam layer covering the skeleton. The fiberglass nylon skeleton has a honeycomb topology structure, which together with the epoxy resin foam layer forms an interlaced adhesive distribution pattern. In some embodiments of the present invention, the cross-sections of the front longitudinal beam body and the front longitudinal beam cover plate are both L-shaped, and the cavity formed inside the connection between the front longitudinal beam body and the front longitudinal beam cover plate is rectangular. In some embodiments of the present invention, the front longitudinal beam reinforcing plate assembly is disposed at the front and middle parts of the cavity structure, and the front longitudinal beam structure adhesive block is disposed at the rear part of the cavity structure.

[0006] In some embodiments of the present invention, the fiberglass nylon skeleton is provided with a front mounting buckle and a rear mounting buckle. The front mounting buckle engages with the mounting holes on the front longitudinal beam reinforcing plate, and the rear mounting buckle engages with the mounting holes on the front longitudinal beam body.

[0007] In some embodiments of the present invention, both the front mounting buckle and the rear mounting buckle are umbrella-shaped buckles, and the front mounting buckle and the rear mounting buckle are located on the front and rear sides of the fiberglass nylon skeleton, respectively, and are staggered vertically.

[0008] In some embodiments of the present invention, the epoxy resin foam layer is integrated onto the glass fiber nylon skeleton through a secondary injection molding process. The honeycomb-shaped positions on the topology of the glass fiber nylon skeleton are not covered with the epoxy resin foam layer, while the remaining front, back, top, and bottom positions are covered with the epoxy resin foam layer.

[0009] In some embodiments of the present invention, the thickness of the epoxy resin foam layer is 2-3 mm, and the gap between the epoxy resin foam layer and the internal cavity of the front longitudinal beam is 3-5 mm. In some embodiments of the present invention, the front longitudinal beam reinforcing plate has an L-shaped cross section, and the shape of the front longitudinal beam reinforcing plate matches the shape of the front and middle parts of the front longitudinal beam body; the front longitudinal beam support plate and the front longitudinal beam reinforcing plate are arranged in parallel within the L-shaped front longitudinal beam reinforcing plate.

[0010] In a second aspect of the invention, a method for installing a rear reinforcement structure of a platform-based front longitudinal beam in a new energy vehicle is provided, comprising: First, spot weld the front longitudinal beam support plate and the front longitudinal beam front reinforcing plate to the front longitudinal beam reinforcing plate respectively. Then, spot weld the front longitudinal beam reinforcing plate to the front longitudinal beam body. After welding, snap the front longitudinal beam structural adhesive block into the mounting holes at the rear end of the front longitudinal beam reinforcing plate and the front longitudinal beam body to form the front longitudinal beam body assembly. The rear reinforcing plate of the front longitudinal beam is spot-welded to the front longitudinal beam cover plate to form the front longitudinal beam cover plate assembly; The front longitudinal beam cover plate assembly is assembled and spot-welded to the front longitudinal beam body assembly to form the front longitudinal beam assembly.

[0011] In some embodiments of the present invention, when the vehicle body passes through the electrophoretic coating drying oven, the epoxy resin foam layer of the front longitudinal beam structural adhesive block is foamed at a high temperature of over 160°C to fill the gap in the rear cavity of the front longitudinal beam, and the high-strength bonding properties of epoxy resin are used to firmly fix the front longitudinal beam body, the front longitudinal beam cover plate and the glass fiber nylon skeleton into a whole.

[0012] One or more technical solutions of the present invention have the following beneficial effects: (1) The present invention strengthens the front longitudinal beam by the synergistic effect of the front longitudinal beam reinforcing plate assembly and the front longitudinal beam structural adhesive block. In the early stage of the collision, the front longitudinal beam reinforcing plate crushes and absorbs energy, and the front longitudinal beam structural adhesive block is not activated. In the middle stage of the collision, the front longitudinal beam support plate prevents instability, the front longitudinal beam reinforcing plate disperses the load, and the glass fiber nylon skeleton begins to deform and absorb energy. In the later stage of the collision, the front longitudinal beam rear reinforcing plate suppresses deformation, and at the same time, the epoxy resin layer is used to bond and strengthen, completely preventing the rear bending, thus solving the problems of rear bending of the front longitudinal beam, battery extrusion and platform adaptation of new energy vehicles.

[0013] (2) The fiberglass nylon skeleton of the present invention forms a “honeycomb” shape through topology optimization, which can reduce weight while ensuring structural strength; the deformation of the honeycomb skeleton absorbs residual energy and reduces the risk of weld cracking; after the epoxy resin foam layer is cured at 160°C, the bonding strength with the sheet metal reaches 25MPa, so that the rear part of the front longitudinal beam forms an integral structure and improves the bending resistance.

[0014] (3) The front longitudinal beam structure rubber block of the present invention is installed by snap-fit. In order to prevent misinstallation of individual units, the snap-fit ​​installation points are arranged in layers at the front and rear and top and bottom. The front installation snap-fit ​​is snapped into the installation hole of the front longitudinal beam reinforcing plate, and the rear installation snap-fit ​​is snapped directly into the installation hole of the front longitudinal beam body, which shortens the installation time, improves the installation efficiency, and facilitates the assembly at the welding site.

[0015] (4) In addition to meeting the frontal and offset collision safety performance of new energy vehicles, this invention also improves the stiffness, modal characteristics, and overall NVH of the vehicle body frame. From a production perspective, the front longitudinal beam rear reinforcement technology has a simple structure, fewer parts, better manufacturing process control, and optimal cost. On the other hand, this technology can be applied to the collision safety requirements of different models on the same platform, while reducing the development cost and cycle of each model. Attached Figure Description

[0016] Figure 1 This is an axial view of the front longitudinal beam assembly provided by the present invention; Figure 2 This is an exploded view of the front longitudinal beam assembly provided by the present invention; Figure 3 This is an axial view of the interior cavity of the front longitudinal beam assembly provided by the present invention; Figure 4 This is an axial view of the front longitudinal beam cover plate assembly provided by the present invention; Figure 5 This is an axial view of the front longitudinal beam structure adhesive block provided by the present invention; Figure 6 This is an axial view of the front longitudinal beam structure adhesive block provided by the present invention; Figure 7 This is an axial view of the front longitudinal beam structure adhesive block provided by the present invention; Figure 8 This is a cross-sectional view of the front longitudinal beam structural adhesive block provided by the present invention inside the sheet metal cavity of the front longitudinal beam; Figure 9 This is a cross-sectional view of the front longitudinal beam structural adhesive block provided by the present invention inside the sheet metal cavity of the front longitudinal beam; In the diagram: 1. Front longitudinal beam assembly; 100. Front longitudinal beam body assembly; 200. Front longitudinal beam cover plate assembly; 11. Front longitudinal beam body; 12. Front longitudinal beam reinforcing plate; 13. Front longitudinal beam support plate; 14. Front reinforcing plate of front longitudinal beam; 15. Front longitudinal beam structural adhesive block; 16. Rear reinforcing plate of front longitudinal beam; 17. Front longitudinal beam cover plate; 151. Fiberglass nylon skeleton; 152. Epoxy resin foam layer; 153. Front mounting buckle; 154. Rear mounting buckle. Detailed Implementation

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0018] Example 1 In a typical embodiment of the present invention, a rear reinforcement structure for the front longitudinal beam of a new energy vehicle platform is proposed, such as... Figures 1 to 9 As shown, it includes a front longitudinal beam body 11, a front longitudinal beam cover plate 17, a front longitudinal beam reinforcing plate 12 assembly, and a front longitudinal beam structural adhesive block 15. The front longitudinal beam body 11 and the front longitudinal beam cover plate 17 are connected to form a cavity structure. The front longitudinal beam reinforcing plate 12 assembly and the front longitudinal beam structural adhesive block 15 are disposed in the cavity structure. The front longitudinal beam reinforcing plate 12 assembly includes a front longitudinal beam reinforcing plate 12, a front longitudinal beam support plate 13, a front longitudinal beam front reinforcing plate 14, and a front longitudinal beam rear reinforcing plate 16. The front longitudinal beam support plate 13 and the front longitudinal beam front reinforcing plate 14 are both connected to the front longitudinal beam reinforcing plate 12. The front longitudinal beam reinforcing plate 12 is connected to the inner surface of the front longitudinal beam body 11. The front longitudinal beam rear reinforcing plate 16 is connected to the rear end of the front longitudinal beam cover plate 17. The front longitudinal beam structural adhesive block 15 includes a fiberglass nylon skeleton 151 and an epoxy resin foam layer 152 covering the skeleton. The fiberglass nylon skeleton 151 has a honeycomb topology structure, which together with the epoxy resin foam layer 152 forms an interlaced adhesive distribution pattern.

[0019] It is understood that the reinforcement structure provided in this embodiment strengthens the front longitudinal beam through the front longitudinal beam reinforcement plate 12 assembly and the front longitudinal beam structural adhesive block 15. The front longitudinal beam reinforcement plate 12 assembly serves to resist collision impact and suppress deformation of the front longitudinal beam. The front longitudinal beam reinforcement plate 14 in the front longitudinal beam reinforcement plate 12 assembly is made of HC340 / 590DP high-strength steel and is arranged at the front of the cavity. It absorbs the initial energy of the collision through crushing deformation and delays the transfer of the impact to the rear battery area. The front longitudinal beam support plate 13 is spot-welded to the front longitudinal beam reinforcement plate 12 to form a truss structure, increasing the support points inside the cavity and preventing the longitudinal beam from becoming unstable and bending. The front longitudinal beam reinforcement plate 12, as the main frame, is made of HC340 / 590DP high-strength steel, distributing the load to each component and improving bending stiffness. The front longitudinal beam rear reinforcement plate 16 is spot-welded to the front longitudinal beam cover plate 17 and is made of HC440 / 780DH ultra-high-strength steel, providing additional rigidity in the rear section after the collision and suppressing rear bending deformation. The front longitudinal beam structural adhesive block 15 serves as an adaptive filler, rear reinforcement, and energy-absorbing buffer. The honeycomb skeleton of the front longitudinal beam structural adhesive block 15 is made of PA6-GF35 material, and the weight is reduced by 40% through topology optimization. The deformation of the honeycomb skeleton absorbs residual energy and reduces the risk of weld cracking. After the epoxy resin foam layer 152 is cured at 160℃, the bonding strength with the sheet metal reaches 25MPa, so that the rear of the front longitudinal beam forms an integral structure and improves the bending resistance.

[0020] In this embodiment, the front longitudinal beam reinforcing plate 12 assembly and the front longitudinal beam structural adhesive block 15 work together to reinforce the front longitudinal beam. In the initial stage of the collision, the front longitudinal beam reinforcing plate 14 is crushed and absorbs energy, while the front longitudinal beam structural adhesive block 15 is not activated. In the middle stage of the collision, the front longitudinal beam support plate 13 prevents instability, the front longitudinal beam reinforcing plate 12 disperses the load, and the fiberglass nylon skeleton 151 begins to deform and absorb energy. In the later stage of the collision, the front longitudinal beam rear reinforcing plate 16 suppresses deformation, and the epoxy resin layer is used for bonding and reinforcement to completely prevent rear bending, thus completely solving the problems of rear bending of the front longitudinal beam, battery extrusion, and platform adaptation in new energy vehicles.

[0021] In this embodiment, the cross-sections of the front longitudinal beam body 11 and the front longitudinal beam cover plate 17 are both L-shaped, and the cavity formed by the connection between the front longitudinal beam body 11 and the front longitudinal beam cover plate 17 is rectangular.

[0022] Understandably, setting the front longitudinal beam as a separate structure of the front longitudinal beam body 11 and the front longitudinal beam cover plate 17 facilitates the assembly of the internal reinforcing plate assembly and the front longitudinal beam structural adhesive block 15. The rectangular cavity formed by the L-shaped front longitudinal beam body 11 and the L-shaped front longitudinal beam cover plate 17 improves the bending stiffness of the cross section, and the collision force transmission path is more uniform, avoiding bending deformation caused by local stress concentration.

[0023] In this embodiment, the front longitudinal beam reinforcing plate 12 assembly is disposed at the front and middle of the cavity structure, and the front longitudinal beam structural adhesive block 15 is disposed at the rear of the cavity structure. The reinforcing plate assembly at the front is responsible for absorbing energy during the initial collision, while the structural adhesive block at the rear resists subsequent impacts, forming a two-stage protection system that effectively improves energy absorption efficiency. In this embodiment, the fiberglass nylon skeleton 151 is provided with a front mounting buckle 153 and a rear mounting buckle 154. The front mounting buckle 153 engages with the mounting holes on the front longitudinal beam reinforcing plate 12, and the rear mounting buckle 154 engages with the mounting holes on the front longitudinal beam body 11. Furthermore, both the front mounting buckle 153 and the rear mounting buckle 154 are umbrella-shaped buckles, located on the front and rear sides of the fiberglass nylon skeleton 151 respectively, and are staggered vertically.

[0024] Understandably, to prevent misinstallation of individual components, the snap-fit ​​installation points of the front longitudinal beam structural adhesive block 15 are arranged in a layered manner, front and rear, top and bottom, as follows: Figure 5 As shown; Figure 9 As shown, the front mounting clip 153 engages with the mounting hole in the front longitudinal beam reinforcing plate 12, and the front longitudinal beam body 11 corresponds to the designed mounting through hole. The gap between the clip mounting limiting surface and the sheet metal of the front longitudinal beam reinforcing plate 12 is 0.5mm. Figure 3 As shown, the rear mounting clip 154 ​​is directly snapped into the mounting hole of the front longitudinal beam body 11. The gap between the clip mounting limiting surface and the sheet metal of the front longitudinal beam body 11 is 0.5mm. The two mounting clips are designed with a 0.5mm gap between them and the sheet metal, which facilitates assembly on the welding site.

[0025] In this embodiment, the adhesive block 15 of the front longitudinal beam is designed with a 3mm gap in the cavity at the rear of the front longitudinal beam, which well meets the flowability of the coating electrophoretic liquid and ensures the anti-corrosion performance of the cavity at the rear of the front longitudinal beam.

[0026] In this embodiment, the epoxy resin foam layer 152 has a thickness of 2-3 mm, and the gap between the epoxy resin foam layer 152 and the internal cavity of the front longitudinal beam is 3-5 mm. Further, the layer is integrated onto the fiberglass nylon skeleton 151 via a secondary injection molding process. The honeycomb-shaped positions on the fiberglass nylon skeleton 151 are not covered by the epoxy resin foam layer 152, while the remaining front, rear, top, and bottom positions are covered by the epoxy resin foam layer 152.

[0027] In one specific embodiment of this example, the fiberglass nylon skeleton 151 is made of PA6-GF35 material with a wall thickness of 2mm; the front mounting buckle 153 and the rear mounting buckle 154 are integrally injection molded with the fiberglass nylon skeleton 151, increasing the strength of the mounting points of the mounting buckles. Figure 7 As shown, the epoxy resin foam layer 152 is then integrated onto the fiberglass nylon skeleton 151 through a secondary injection molding process. Except for the "honeycomb" shaped areas of the fiberglass nylon skeleton 151 where no foam layer is needed, epoxy resin foam needs to be applied to the top, bottom, left, and right sides of the fiberglass nylon skeleton 151. Figure 8 As shown, the epoxy resin foam layer 152 has a thickness of 2.5 mm. Meanwhile, to accommodate different cross-sectional sizes of the rear cavity of the front longitudinal beam, the gap between the epoxy resin foam layer 152 and the rear cavity of the front longitudinal beam is 3.0 mm, and the foaming ratio of the epoxy resin foam layer 152 is ≥200%. When the body-in-white passes through the electrophoretic coating drying oven, the epoxy resin foam layer 152, after being foamed at a high temperature above 160℃, fills the gap of the rear cavity of the front longitudinal beam. Utilizing the high-strength bonding properties of epoxy resin, it firmly fixes the front longitudinal beam body 11, the front longitudinal beam cover plate 17, and the fiberglass nylon skeleton 151 into a single unit, thereby providing structural reinforcement. This design is suitable for different vehicle models on the same platform with varying rear cavity cross-sectional arrangements.

[0028] In this embodiment, the front longitudinal beam reinforcing plate 12 has an L-shaped cross section, and the shape of the front longitudinal beam reinforcing plate 12 matches the shape of the front and middle parts of the front longitudinal beam body 11; the front longitudinal beam support plate 13 and the front longitudinal beam front reinforcing plate 14 are arranged in parallel within the L-shaped front longitudinal beam reinforcing plate 12.

[0029] In this embodiment, the front longitudinal beam body 11, the front longitudinal beam cover plate 17, and the front longitudinal beam rear reinforcing plate 16 are made of HC440 / 780DH high-strength steel, while the front longitudinal beam reinforcing plate 12 and the front longitudinal beam front reinforcing plate 14 are made of HC340 / 590DP high-strength steel. The front longitudinal beam structural adhesive block 15 is composed of a polymer composite material, which includes a glass fiber nylon skeleton 151PA6-GF35 and an epoxy resin mixture foam material, and is formed by injection molding. This product features high strength, high rigidity, and high adhesion. After electrophoretic curing in the painting workshop, the epoxy resin foam layer 152 bonds to the sheet metal surface, achieving a compressive strength of 20-25 MPa and a shear strength of 3-5 MPa. The fiberglass nylon skeleton 151 adopts a honeycomb structure and is designed with umbrella-shaped clips for pre-fixation, with a skeleton thickness of 2 mm. The epoxy resin foam layer 152 is applied to the surface of the fiberglass nylon skeleton 151 through secondary injection molding and is designed with an alternating adhesive distribution structure, which reduces weight while ensuring structural strength. The adhesive layer thickness is designed to be 2.5 mm. The structural adhesive block is fixed to the rear cavity of the front longitudinal beam sheet metal using umbrella-shaped clips, with a 3.0-5.0 mm gap between it and the sheet metal cavity for electrophoretic coating. When the car body passes through the electrophoretic coating drying oven, the epoxy resin of the front longitudinal beam structural rubber block 15 is foamed at high temperature to fill the gaps reserved in the cavity, and the high-strength bonding properties of epoxy resin are used to combine the front longitudinal beam body 11 with the front longitudinal beam reinforcing plate 12 assembly and the front longitudinal beam cover plate 17 assembly 200 into a whole, so that the rear of the front longitudinal beam will not bend during the collision, and can absorb more energy.

[0030] The rear reinforcement structure of the front longitudinal beam in this embodiment for new energy vehicles, with the front longitudinal beam structural adhesive block 15 arranged in the rear cavity of the front longitudinal beam assembly 1, plays a role in buffering and absorbing energy during frontal or offset collisions due to the honeycomb-shaped fiberglass nylon skeleton 151 of the front longitudinal beam structural adhesive block 15. Simultaneously, the high-strength bonding between the epoxy resin foam layer 152 and the rear cavity of the front longitudinal beam increases the stiffness of the rear section of the front longitudinal beam, effectively preventing the weld points of the front longitudinal beam body assembly 11 and the front longitudinal beam cover plate assembly 200 from cracking due to collision. Ultimately, this avoids safety issues such as large front compartment intrusion caused by bending of the rear of the front longitudinal beam and thermal runaway caused by battery pack compression.

[0031] Example 2 In a typical embodiment of the present invention, a method for installing a rear reinforcement structure of a platform-based front longitudinal beam in a new energy vehicle is provided, comprising: First, spot weld the front longitudinal beam support plate and the front longitudinal beam front reinforcing plate to the front longitudinal beam reinforcing plate respectively. Then, spot weld the front longitudinal beam reinforcing plate to the front longitudinal beam body. After welding, snap the front longitudinal beam structural adhesive block into the mounting holes at the rear end of the front longitudinal beam reinforcing plate and the front longitudinal beam body to form the front longitudinal beam body assembly. The rear reinforcing plate of the front longitudinal beam is spot-welded to the front longitudinal beam cover plate to form the front longitudinal beam cover plate assembly; The front longitudinal beam cover plate assembly is assembled and spot-welded to the front longitudinal beam body assembly to form the front longitudinal beam assembly.

[0032] Furthermore, when the car body passes through the electrophoretic coating drying oven, the epoxy resin foam layer of the front longitudinal beam structural adhesive block is foamed at a high temperature of over 160°C to fill the gap in the rear cavity of the front longitudinal beam, and the high-strength bonding properties of epoxy resin are used to firmly fix the front longitudinal beam body, the front longitudinal beam cover plate and the glass fiber nylon skeleton into a whole.

[0033] This embodiment achieves the installation of the reinforced structure through spot welding and snap-fit ​​assembly, which can effectively improve assembly efficiency and shorten assembly time; the graded assembly reduces component error, improves dimensional qualification rate, and ensures product quality; in addition, the existing painting line's 160℃ baking triggers epoxy resin foaming to complete the structure, so that the bonding strength between the glue block and the sheet metal reaches 25MPa, realizing a metal-non-metal composite structure, which saves the investment cost of special curing equipment compared with traditional solutions.

[0034] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A platform-based front longitudinal beam rear reinforcement structure for new energy vehicles, characterized in that, Includes the front longitudinal beam body, the front longitudinal beam cover plate, the front longitudinal beam reinforcing plate assembly, and the front longitudinal beam structural adhesive block; The front longitudinal beam body and the front longitudinal beam cover plate are connected to form a cavity structure. The front longitudinal beam reinforcing plate assembly and the front longitudinal beam structural adhesive block are disposed within the cavity structure. The front longitudinal beam reinforcing plate assembly includes a front longitudinal beam reinforcing plate, a front longitudinal beam support plate, a front reinforcing plate, and a rear reinforcing plate. The front longitudinal beam support plate and the front reinforcing plate are both connected to the front longitudinal beam reinforcing plate. The front longitudinal beam reinforcing plate is connected to the inner surface of the front longitudinal beam body. The rear reinforcing plate is connected to the rear end of the front longitudinal beam cover plate. The front longitudinal beam structural adhesive block includes a fiberglass nylon skeleton and an epoxy resin foam layer covering the skeleton. The fiberglass nylon skeleton has a honeycomb topology structure, which together with the epoxy resin foam layer forms an interlaced adhesive distribution pattern.

2. The rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 1, characterized in that, Both the front longitudinal beam body and the front longitudinal beam cover plate have L-shaped cross sections, and the cavity formed inside the connection between the front longitudinal beam body and the front longitudinal beam cover plate is rectangular.

3. The rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 1, characterized in that, The front longitudinal beam reinforcing plate assembly is located at the front and middle of the cavity structure, and the front longitudinal beam structure adhesive block is located at the rear of the cavity structure.

4. The rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 1, characterized in that, The fiberglass nylon skeleton is provided with a front mounting buckle and a rear mounting buckle. The front mounting buckle engages with the mounting holes on the front longitudinal beam reinforcing plate, and the rear mounting buckle engages with the mounting holes on the front longitudinal beam body.

5. The rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 4, characterized in that, Both the front and rear mounting clips are umbrella-shaped clips, located on the front and rear sides of the fiberglass nylon skeleton, respectively, and are staggered vertically.

6. The rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 1, characterized in that, The epoxy resin foam layer is integrated onto the fiberglass nylon skeleton through a secondary injection molding process. The honeycomb-shaped positions on the fiberglass nylon skeleton are not covered with the epoxy resin foam layer, while the remaining front, back, top, and bottom positions are covered with the epoxy resin foam layer.

7. The rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 1, characterized in that, The epoxy resin foam layer has a thickness of 2-3 mm, and the gap between the epoxy resin foam layer and the internal cavity of the front longitudinal beam is 3-5 mm.

8. The rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 1, characterized in that, The front longitudinal beam reinforcing plate has an L-shaped cross section, and the shape of the front longitudinal beam reinforcing plate matches the shape of the front and middle parts of the front longitudinal beam body; the front longitudinal beam support plate and the front longitudinal beam reinforcing plate are arranged in parallel within the L-shaped front longitudinal beam reinforcing plate.

9. A method for installing the rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in any one of claims 1-8, characterized in that, include: First, spot weld the front longitudinal beam support plate and the front longitudinal beam front reinforcing plate to the front longitudinal beam reinforcing plate respectively. Then, spot weld the front longitudinal beam reinforcing plate to the front longitudinal beam body. After welding, snap the front longitudinal beam structural adhesive block into the mounting holes at the rear end of the front longitudinal beam reinforcing plate and the front longitudinal beam body to form the front longitudinal beam body assembly. The rear reinforcing plate of the front longitudinal beam is spot-welded to the front longitudinal beam cover plate to form the front longitudinal beam cover plate assembly; The front longitudinal beam cover plate assembly is assembled and spot-welded to the front longitudinal beam body assembly to form the front longitudinal beam assembly.

10. The installation method of the rear reinforcement structure of the front longitudinal beam of a new energy vehicle platform as described in claim 9, characterized in that, When the car body passes through the electrophoresis drying oven, the epoxy resin foam layer of the front longitudinal beam structural adhesive block is foamed at a high temperature of over 160°C to fill the gap in the rear cavity of the front longitudinal beam. The high-strength bonding properties of epoxy resin are used to firmly fix the front longitudinal beam body, the front longitudinal beam cover plate and the glass fiber nylon skeleton into a whole.

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