Composite material door system and construction method thereof

Abstract

The present invention provides a composite door system and a construction method thereof, the composite door system comprising: a door inner panel; an insert assembly; a door window frame assembly; a door outer panel bracket; and a door outer panel; wherein the door inner panel, the door outer panel bracket and the door outer panel are all made of composite materials. A composite door system and a construction method thereof provided by the present invention can simultaneously meet multiple requirements such as lightweighting of the entire vehicle, diversified shapes, simplified assembly, and rapid maintenance, and will be more suitable for doors of new energy electric vehicles and self-driving vehicles in the future.

Description

Technical Field

[0001] The present invention relates to the field of automobiles, and more particularly to a composite material door system and a construction method thereof. Background Art

[0002] At present, in the traditional vehicle design, whether it is the inner and outer panels of the car door or the load-bearing parts, steel plates or aluminum alloy plates are still used for stamping and robot hemming to connect the inner and outer panels. Steel plates are made of sheet metal materials. Although they have the advantages of good toughness and high strength, they are too heavy and there are certain difficulties in disassembly and assembly in the future. Most of the stamping materials are cold-rolled steel plates. If the parts stamped out of cold-rolled steel plates are often exposed to the air, the surface of the parts is easy to oxidize. When using the parts, it takes a lot of time to perform surface treatment, electrophoresis, and painting.

[0003] Now, with the development of the automobile industry, the current society pays more and more attention to the lightweight requirements of automobiles. In the era of widespread use of electric vehicles, in order to improve the performance requirements of the entire vehicle, increase the cruising range of electric vehicles, and the requirements for more intelligence of future smart cars are getting higher and higher, the traditional door structure has been difficult to adapt to the demand.

[0004] First, the traditional production process requires large equipment investment, the coating process is relatively complex, the overall layout of the production line is long, and the production cycle cannot be greatly improved. Secondly, as the personalized needs of buyers gradually increase, a single product positioning is difficult to meet customer needs. Limited by the automobile door process, the personalized needs of traditional models for door styling are very limited and cannot better meet customer needs. Finally, in a traffic accident, once a traditional sheet metal door is damaged, it is very difficult to repair or the entire door must be replaced directly, resulting in high repair costs for consumers. This is contrary to the important development direction of lightweight, diversified styling, simplified assembly, and rapid maintenance of the entire vehicle. Summary of the invention

[0005] The purpose of the present invention is to provide a composite door system and a construction method thereof, so as to solve the problem in the prior art that automobile doors cannot simultaneously meet multiple requirements such as lightweight of the entire vehicle, diversified styling, simplified assembly, and rapid maintenance.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0007] According to a first aspect of the present invention, a composite door system is provided, comprising: a door inner panel; an insert assembly; a door window frame assembly; a door outer panel bracket; and a door outer panel; wherein the door inner panel, the door outer panel bracket and the door outer panel are all made of composite materials.

[0008] The insert assembly is assembled and welded by a door window frame insert, a B-pillar trim insert, a door hinge area insert, a door water-cut window sill insert, and a door threshold insert.

[0009] The door inner panel has different reinforcing rib shapes in different areas where the door window frame insert, the B-pillar trim insert, the door hinge area insert, the door water-cut window sill insert, and the door threshold insert are located.

[0010] The insert assembly is integrally molded with the vehicle door inner panel by injection molding to form the vehicle door inner panel assembly.

[0011] The vehicle door window frame assembly includes: a vehicle door window frame sealing plate, a B-pillar trim, a glass front rail and a glass rear rail, wherein the vehicle door window frame sealing plate and the B-pillar trim are bonded to the vehicle door inner panel, and the glass front rail and the glass rear rail are screwed or riveted to the vehicle door inner panel.

[0012] The composite door system also includes a door anti-collision beam that is screwed or riveted to the door inner panel assembly.

[0013] The vehicle door outer panel bracket is connected to the vehicle door inner panel via mushroom nails and anti-theft screws.

[0014] The edges of the vehicle door outer panel and the vehicle door inner panel are sealed by sealing cotton.

[0015] The exterior surface of the vehicle door outer panel has false seams to achieve color separation and / or component separation.

[0016] The composite materials suitable for the present invention include: PP+EPDM-TD30, PP-GF30, PP-GF40, SMC, and ASA.

[0017] According to a second aspect of the present invention, a method for constructing a composite door system as described above is provided, comprising the following steps: 1) assembling and welding a door window frame insert, a B-pillar trim insert, a door hinge area insert, a door water-cut window sill insert, and a door threshold insert into an insert assembly; 2) providing a door inner panel, and forming a door inner panel assembly by injection molding the insert assembly and the door inner panel as an integral insert; 3) providing a door window frame assembly, comprising: a door window frame sealing plate, a B-pillar trim, a glass front rail, and a glass rear rail, and assembling and welding the door window frame assembly with the door inner panel; The invention relates to a vehicle door outer panel assembly; 4) providing a vehicle door anti-collision beam, screwing or riveting the vehicle door anti-collision beam to the vehicle door inner panel assembly; 5) providing a vehicle door outer panel bracket and a vehicle door outer panel, bonding the vehicle door outer panel bracket to the inner side of the vehicle door outer panel; 6) providing a vehicle door outer water-cut window sill beam with an integrated outer door handle metal reinforcement plate, bonding it to the inner side of the upper end of the vehicle door outer panel to form a vehicle door outer panel assembly; and 7) connecting the vehicle door outer panel assembly to the vehicle door inner panel assembly by fasteners, and the edges of the vehicle door outer panel and the vehicle door inner panel are sealed by sealing cotton.

[0018] According to the present invention, a vehicle door is provided that can be more suitable for new energy electric vehicles and self-driving vehicles in the future, meet the demand for lightweight vehicles, improve the range of electric vehicles, and at the same time meet multiple important directions such as diversified styling, simplified assembly, and rapid maintenance.

[0019] According to the present invention, it is proposed for the first time to apply the insert injection molding process to the automobile side door, breaking through the single sheet metal material of automobile doors for a hundred years, providing more possibilities for meeting the lightweight requirements of automobiles, and changing the shortcomings brought by traditional metal doors, such as: easy to rust, visible welds, weld marks and welding seams, unsightly gray areas, easy bulging, cracking and falling off of paint at welds, numerous parts, heavy doors, high costs and other defects.

[0020] According to a composite door inner panel provided by the present invention, the main structure on the lower side of the door inner panel and the window frame area of ​​the door inner panel are integrated into an independent part. One of its advantages is that the exposed inner panel appearance surface on one side of the composite door inner panel is no longer limited to the color of the whole vehicle like sheet metal doors or aluminum alloy doors. The composite door inner panel of the present invention can be completely independent of the whole vehicle painting process, that is, the color and surface treatment of the exposed inner panel appearance surface on one side of the composite door inner panel can be customized, for example, customized spraying of high-end colors or leather grain paint and leather grain surface treatment that are different from the color of the vehicle body. One of the other advantages is that the welds and weld point prints of the door inner panel in the window frame and the main body of the door inner panel can be discarded, which also greatly improves the corrosion protection of the door inner panel caused by welding or paint cracking.

[0021] According to the insert assembly provided by the present invention, the profile of each independent insert is completely matched with the profile of the inner door panel. In the door sealing surface area, sheet metal inserts with concave-convex or bent cross-sections with a certain strength are designed. The segmented insert design can save costs more than the integral design and reduce the generation of sheet metal waste. In addition, the insert design in different regions is more flexible. Different grades of metal inserts can be used in different regions, and different insert material thicknesses can be designed for the key performance of necessary regions.

[0022] According to the performance requirements of different regions of the door, the present invention also designs the reinforcing rib connection scheme of the composite material inner door panel into different reinforcing rib forms, and arranges stronger reinforcing ribs to press the metal insert, so that it can be better integrated with the composite material inner door panel and will not break away under any working conditions. For example, different grid-shaped reinforcing rib connection forms are designed. For regions with high stiffness requirements such as the vehicle window frame and the inner window sill of the door, it can better press the metal sheet metal insert assembly and the composite material inner panel to form an integral inner door panel with high strength, strong rigidity and meeting the requirements of bonding force, meeting the key attention positions of customers.

[0023] According to the composite material outer door panel in the composite material outer door panel assembly provided by the present invention, there is a false seam feature in the appearance surface on the lower side. After the vehicle outer door panel is designed by the composite material outer panel, the plasticity of the shape is improved. Not only can different colors and patterns of the outer door panel be customized, but also the split design can be carried out. Similarly, it also provides more possibilities and contribution values for the intelligent human-machine interaction carrier of the door, intelligent vehicle exterior lighting and vehicle body aerodynamics.

[0024] In short, according to a composite material door system and its construction method provided by the present invention, it can simultaneously meet various requirements such as the development of vehicle lightweight, shape diversification, assembly simplification, and maintenance rapidization, and is more suitable for the doors of new energy electric vehicles and autonomous driving vehicles in the future. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic structural diagram of the composite material door assembly of the present invention;

[0026] Figure 2 It is an exploded view of the composite material door assembly of the present invention;

[0027] Figure 3 It is a schematic diagram of a single integral part formed after the composite material inner door panel and the sheet metal insert of the present invention are integrally injection molded;

[0028] Figure 4 It is a schematic diagram of a metal sheet metal insert assembly similar to the shape of a Chinese character 'Ri' in the composite material door of the present invention;

[0029] Figure 5 It is a schematic structural diagram of a door hinge area in a composite material door of the present invention;

[0030] Figure 6 A reinforcing rib connection scheme for the metal sheet metal insert assembly and the composite material inner panel integral mold insert injection molding in the composite material vehicle door of the present invention;

[0031] Fig. 7A and Figure 7B They are respectively an enlarged view of the reinforcing rib details and a structural cross-sectional view of the window frame area of ​​the composite material vehicle door inner panel of the present invention;

[0032] Fig. 8A and Figure 8B They are respectively an enlarged view of the reinforcement rib details and a structural cross-sectional view of the B-pillar trim area of ​​the composite material door inner panel of the present invention;

[0033] Fig. 9A and Fig. 9B They are respectively an enlarged view of the reinforcement rib details and a structural cross-sectional view of the water-cut window sill area in the composite material vehicle door inner panel of the present invention;

[0034] Fig. 10A and Fig. 10B They are respectively an enlarged view of the reinforcing rib details and a structural cross-sectional view of the sill area of ​​the composite material vehicle door inner panel of the present invention;

[0035] Fig.11A and Fig. 11B The enlarged view of the reinforcing rib details and the structural cross-sectional view of the hinge area of ​​the composite material vehicle door inner panel of the present invention;

[0036] Fig.12 The installation positions and schematic diagram of the composite material door of the present invention, including the window frame sealing plate on the A-pillar side, the B-pillar trim, the composite material front and rear glass auxiliary guide rails, and the anti-collision beam;

[0037] Fig.13 This is a schematic diagram showing that the window frame sealing plate and the B-pillar decorative plate on the A-pillar side of the composite material vehicle door of the present invention have been installed and matched;

[0038] Fig.14 This is a cross-sectional view of the structural details of the window frame sealing plate on the A-pillar side of the composite material vehicle door of the present invention.

[0039] Fig.15 A cross-sectional view showing the position and structural details of the B-pillar trim panel of the composite door of the present invention;

[0040] Fig.16 It is a schematic diagram of the composite material vehicle door outer panel assembly of the present invention;

[0041] Fig.17A and Fig. 17BA schematic diagram and a detailed cross-sectional diagram of a door outer panel in the composite material door outer panel assembly of the present invention;

[0042] Fig.18A and Fig.18B It is a simple schematic diagram of other possible variant shapes of the composite material door inner panel insert of the present invention. DETAILED DESCRIPTION

[0043] The present invention is further described below in conjunction with specific examples. It should be understood that the following examples are only used to illustrate the present invention and are not used to limit the scope of the present invention.

[0044] like Figure 1 FIG. 1 is an overall schematic diagram of a composite door system 100 provided according to a preferred embodiment of the present invention. Through the transparent outer panel, the structure and arrangement of the main parts in the door cavity except for the glass and the glass lifter and other accessories can be clearly seen. The following is a detailed description of the various details of the composite door system 100:

[0045] like Figure 2 The figure shows an exploded view of the composite door system assembly 100 of the present invention. As shown in the figure, the composite door system 100 includes: a composite door inner panel 10; a metal sheet metal insert assembly 20; a door window frame assembly 30; a composite door outer panel bracket 40; and a composite door outer panel 50. It can intuitively show the steps and hierarchical structure of the main structure of the door system, except for the accessories such as the motor, wire rope, pulley, and winding wheel in the glass and glass lifter assembly; the structure can be split into a composite door outer panel assembly, a composite door inner panel assembly, and a safety-related load-bearing structural member, the door anti-collision beam.

[0046] Figure 3 Shows Figure 4After the metal sheet metal insert assembly 20 in the shape of a Chinese character "Ri" shown in the figure is integrally molded by insert injection with the composite material door inner panel 10, a new composite material door inner panel with a metal insert attached inside is formed, which is the composite material door inner panel assembly 101. Through the above-mentioned composite material insert injection molding process, the door inner panel made of traditional metal materials is completely replaced by a composite material door inner panel. And by means of metal inserts in necessary areas and optimized structural design of the inner panel, the overall rigidity and strength of the door are enhanced to meet the load-bearing performance requirements of the door during the entire life cycle of the door assembly system, such as its own weight and door sag. Its innovation points are as follows: a. The insert injection process is innovative in automotive side doors; b. It breaks through the singularity of automotive door panels being made of sheet metal for a hundred years; c. It provides more possibilities for meeting automotive lightweight requirements; d. It changes the deficiencies brought by traditional metal doors, such as being prone to rust, welds, weld marks and visible welding seams, unsightly gray areas, paint on welds being prone to bulging, cracking and peeling, numerous parts, heavy door weight and high cost. The difficulties it overcomes are as follows: a. It breaks through the mandatory safety regulation standards for automotive side doors; b. It meets the various performance indicators of the automotive side door subsystem; c. It solves the pain point of sheet metal being difficult to further reduce weight; d. It has a more competitive advantage in terms of weight and cost compared with aluminum alloy doors, and also breaks through the prejudice in customers' minds that plastic side doors are definitely unsafe for a long time.

[0047] Figure 4 The metal sheet metal insert assembly 20 in the shape of a Chinese character "Ri" shown in the figure is composed of five segments, just like the composition of the Chinese character "Ri", including a door hinge area sheet metal insert 21, a window frame sheet metal insert 22, a door lock B-pillar side sheet metal insert 23, a door inner water cut sill sheet metal insert 24 and a door sill sheet metal insert 25, which are assembled and welded by five segmented sheet metal inserts. The surface of each independent sheet metal insert completely matches the surface of the door inner panel. In the door sealing surface area, sheet metal inserts with certain strength unevenness or bent cross-sections are designed. The segmented sheet metal insert design can save more costs and reduce the generation of sheet metal waste compared with the integral design; in addition, the segmented sheet metal insert design in different regions is more flexible. Different grades of metal inserts can be used in different regions, and different sheet metal insert material thicknesses can be designed for the key performance in necessary regions. For example, as Figure 5 shown, the door hinge area is the key performance area. The basic material thickness of the door hinge area sheet metal insert substrate 211 is the same as that of the other five segmented sheet metal inserts, all being 0.7 mm. In the hinge area, the hinge insert substrate 211 overlaps with the hinge reinforcement plate 212 and the limiter reinforcement plate 213. The basic material thicknesses of the hinge reinforcement plate 212 and the limiter reinforcement plate 213 are 2.0 mm, which can thus improve the overall load-bearing requirements of the door. Its innovation points are as follows: The segmented sheet metal insert design can save more costs and reduce the generation of sheet metal waste compared with the integral design; the segmented sheet metal insert design in different regions is more flexible.

[0048] Figure 6 It shows a reinforcing rib connection solution of in-mold insert injection molding of a metal sheet metal insert assembly 20 in the shape of a Chinese character 'Ri' and a composite material door inner panel 10 integrally. According to the performance requirements of different areas of the door, the reinforcing rib connection solution of the composite material door inner panel 10 is designed into different reinforcing rib forms, and stronger reinforcing ribs are arranged to press the metal insert, so that it can be better integrated with the composite material door inner panel and will not break away under any working conditions. For example, different grid-shaped reinforcing rib connection forms are designed. For areas with high stiffness requirements such as the door window frame and the inner window sill of the door, it can better press the metal sheet metal insert assembly and the composite material inner panel to form an integral door inner panel with high strength, strong rigidity and satisfactory bonding force, meeting the key attention positions of customers. Figure 6 It shows five key reinforcing rib areas. Figure 7A to Figure 11B It respectively shows the detailed enlarged views and structural sectional views of each reinforcing rib. The grid-shaped reinforcing ribs designed in the present invention are only the optimal case in this example, but are not limited to this form, and can include various grid shapes, such as hexagons, triangles, circles, squares, rhomboids, etc. The innovation lies in: designing different in-mold insert injection molding reinforcing ribs for the composite material inner panel according to different positions, different working conditions and different performance requirements of different areas of the door to make the integration of the door inner panel body and the metal sheet metal insert more integrated, and at the same time it is more convenient for adjustment and design.

[0049] Among them Figure 6 It also shows another inventive point of the present invention, that is, the composite material door inner panel 10 in the present invention is completely enclosed in the area of the glass lifter assembly, and this closed area integrates the front guide rail, the rear guide rail, the seat plate of the motor pulley and the mounting point structures of the four pulleys in the glass lifter assembly. This integrated technical solution in the glass lifting area complements the composite material door inner panel 10 and is integrally injection molded with the composite material door inner panel. The solution of this inventive technical point is neither the same as the solution of the sheet metal door, where the glass lifter is installed on the metal door inner panel and requires process holes for installation, debugging and maintenance to be opened on the sheet metal door inner panel, nor the same as the door inner panel door module solution in recent years, where the glass lifter assembly is integrated on a split plastic mounting plate. This structural design solution reduces the number of parts in the door assembly, and at the same time makes great contributions and advantages to the lightweight of the whole vehicle and cost reduction. The innovative improvement points are: a. Meeting the important development direction of simple door assembly and fast repair in the future; b. Improving the sound quality of the car door; c. The number of parts is reduced, the unit cost of the door drops a lot, and the mold inspection tools are also correspondingly reduced.

[0050] Such as Figure 2 and Fig.12As shown, a vehicle door window frame assembly 30 is also shown, including: a vehicle door window frame cover plate 31, a B-pillar trim plate 32, a glass front rail 33 and a glass rear rail 34. A vehicle door anti-collision beam 35 screwed or riveted to the vehicle door inner panel assembly is also shown. Fig.12 The installation sequence of the composite door inner panel 10, the door window frame sealing plate 31 in the A-pillar area and the B-pillar trim plate 32 in the B-pillar area is also shown, wherein the door window frame sealing plate 31 and the B-pillar trim plate 32 are both bonded by glue 36. Figure 3 The composite door inner panel assembly 101 is shown. Figure 13 to Figure 15 As shown in the figure, after bonding, the door window frames form closed cavities in the A-pillar area and the B-pillar area. This structure and parts installation scheme is used to improve the rigidity of the window frame area and the strength of the window frame area under all working conditions of the door assembly to meet the door performance requirements. Its innovative improvements are: a. A new design scheme for sheet metal inserts in the composite side door window frame area is proposed; b. The problem of insufficient window frame rigidity caused by replacing the traditional metal material with a composite material is solved; c. The technical difficulty of matching the window frame sealing strip in this area is innovatively solved.

[0051] in addition, Fig.12 It is shown that the composite material front and rear auxiliary guide rails of the window glass are integrated at the corresponding position of the composite material door inner panel, and the installation points are installed by screws to meet the installation of the front and rear glass guide rails 33 and 34, improve the stability of the glass lifting and the door sound quality of the door glass lifting; the door anti-collision beam 35 is screwed or riveted to the corresponding position of the composite material door inner panel assembly by screws, so as to meet the composite material door in static extrusion and side collision to provide safety protection for the members in the car. Its innovative improvements are: the number of parts is reduced, the cost of each door is greatly reduced, and the mold inspection fixtures are also reduced accordingly.

[0052] Fig.16 The structure of the composite door outer panel assembly is shown, including a composite door outer panel 50, a composite door outer panel bracket 40, and a door outer water-cut window sill beam 60 integrated with an outer door handle metal reinforcement plate 61. Ten connection structures connected to the composite door inner panel 10 are provided on the composite door outer panel bracket 40. The connection structure includes 8 adaptive and detachable mushroom nail installation points to clamp the composite door inner panel 10, and is also provided with two cross positioning pins with a guide structure at the top to facilitate the positioning and normal assembly of the composite door outer panel bracket 40 and the assembly. The connection structure also includes 2 anti-slip and anti-theft screw points to be screwed on the composite door inner panel 10.

[0053] In addition, the composite door outer panel bracket 40 is bonded to the inner side of the composite door outer panel 50 by a composite adhesive. Similarly, the door outer water-cut window sill beam 60 with an integrated outer door handle metal reinforcement plate 61 is bonded to the inner side of the upper end of the composite door outer panel 50 by a composite adhesive. Among them, the outer water-cut window sill beam 60 of the door outer panel is provided with two anti-slip and anti-theft screw points at both ends to connect to the composite door inner panel 10, which can also better improve the inner and outer stiffness of the door outer water-cut window sill beam; the outer door handle metal reinforcement plate 61 and the outer water-cut window sill beam 60 are integrally molded by injection molding, forming a new composite outer water-cut window sill beam 60 with a metal insert. The metal reinforcement plate 61 can also be bonded to the composite outer water-cut window sill beam 60 by a composite adhesive. The outer door handle metal reinforcement plate 61 close to the door lock is locked on the composite door inner panel 10 through three screw points in the door lock area when the door lock is installed. The outer door handle metal reinforcement plate 61 also has the function of improving the rigidity and safety of the door handle area of ​​the car door, and is used to ensure that the door handle is kept in the correct position during and after an accidental collision, thereby ensuring that the outer door handle area is not damaged and the door lock is not opened, protecting the safety of the passengers in the car. Its innovative improvements are: a. Innovatively invented the connection, fastening and assembly strategy between the composite material door outer panel assembly and the composite material door inner panel assembly; b. Innovatively solved the connection scheme between the composite material door outer panel and the composite material door inner panel in different areas; c. Innovatively designed the anti-theft and anti-falling technical points of the composite material door outer panel.

[0054] The edge of the composite door outer panel 50 is designed with sealing foam 51 adhered to the edge of the door outer panel. When the composite door outer panel 50 is assembled to the composite door inner panel 10, the sealing foam 51 adhered to the outer panel is solidified to form an elastic semicircular sealing foam. At the same time, as the assembly force of the screw connection and the clamp connection to the inner panel is applied, the semicircular sealing foam 51 will be compressed into an oblong shape to achieve a sealing effect. The innovative improvement is that it meets the sealing problem of the composite door assembly.

[0055] Fig.17A and Fig. 17B The composite door outer panel 50 in the composite door outer panel assembly has a styling false seam feature 52 on the exterior surface on the lower side, which reflects the characteristics of the door outer panel having parts or color separation in this area. The core of this is that it is different from the design concept of traditional doors. It is not necessary to separate other parts from the door outer panel independently. It is only necessary to define different colors or surface treatment processes in the upper and lower areas of the false seam feature. Such a design can reduce the number of parts and the weight of the door assembly on the basis of meeting the shape of the whole vehicle, and can also reduce the cost of the whole vehicle and have a certain effect. Fig.17AOnly a simple feature of the composite material outer door panel 50 in this embodiment is shown. After the automotive outer door panel 50 is designed with a composite material outer panel, the plasticity of the styling is improved. It can not only customize different colors and patterns of the outer door panel, but also carry out patchwork design; it also provides more possibilities and contribution values for the intelligent human-machine interaction carrier of the door, intelligent exterior lighting of the vehicle door, and vehicle body aerodynamics. The innovation and improvement lies in: the invention of the composite material door provides more integrated, private customized, intelligent carrier and other solutions for the outer door panel and future intelligent vehicles.

[0056] For example, as Fig.18A and Fig.18B shown in the schematic diagram case, the "Ri" (日)-shaped metal sheet metal insert assembly 20 described in the present invention can actually be evolved into a similar "Shuan" (闩)-shaped insert assembly 20', "Kuang" (冂)-shaped, "Mao" (冃)-shaped, and can also be evolved into a similar "Kou" (口)-shaped insert assembly 20 in the case of a composite material frameless door; in addition to the change in the appearance shape of the insert, the change in the material of the insert, such as replacing the sheet metal insert with an insert made of carbon fiber and other materials, is within the protection scope of the present invention.

[0057] According to a preferred embodiment of the present invention, the assembly process of the embodiment of the present invention is as follows:

[0058] First, weld and assemble the "Ri" (日)-shaped metal sheet metal insert assembly 20 in the composite material door. After integrally injection molding with the insert of the composite material door inner panel 10, it forms a composite material door inner panel assembly 101 with the composite material door inner panel 10;

[0059] Next, place the composite material door inner panel 10 with the insert into the mold, and bond the window frame sealing plate 31 of the door A-pillar and the door B-pillar trim 32;

[0060] Then, screw the composite material window glass front guide rail 33, glass rear guide rail 34, and door anti-collision beam 35 of the window glass. In addition, install parts such as the door hinge, limiter, motor, pulley, lifting sliding support block, winding wheel attachment, glass sealing strip, glass, and door lock on the composite material door inner panel 10 from the outside of the composite material door inner panel 10;

[0061] Next, bond the composite material outer door panel bracket 40 to the inside of the composite material outer door panel 50, and the outer door water cut sill beam 60 integrated with the outer door handle metal reinforcement plate 61 is bonded to the inside of the upper end of the composite material outer door panel 50 through a composite adhesive to form a composite material outer door panel assembly 102;

[0062] Finally, the composite door outer panel assembly 102 is clamped on the composite door inner panel 10 by adaptive and detachable mushroom nail fasteners, and there are also 4 anti-slip and anti-theft screws screwed on the composite door inner panel 10, and the edge matching area of ​​the composite door outer panel 50 and the composite door inner panel 10 is matched by sealing cotton 51 to achieve the overall sealing performance of the composite door system.

[0063] The above is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. The above embodiments of the present invention can also be modified in various ways. All simple, equivalent changes and modifications made according to the claims and the description of the present invention fall within the scope of protection of the claims of the present invention. The contents not described in detail in the present invention are all conventional technical contents.

Claims

1. A composite door system, characterized in that: include: Door inner panels; Insert assembly; Door window frame assembly; Door outer panel bracket; as well as Door outer panels; Wherein, the door inner panel, the door outer panel bracket and the door outer panel are all made of composite materials; The insert assembly is assembled and welded by a door window frame insert, a B-pillar trim insert, a door hinge area insert, a door water-cut window sill insert, and a door threshold insert; The door inner panel has different reinforcing rib shapes in different areas where the door window frame insert, the B-pillar trim insert, the door hinge area insert, the door water-cut window sill insert, and the door threshold insert are located; The insert assembly is integrally molded with the vehicle door inner panel by injection molding to form the vehicle door inner panel assembly.

2. The composite door system according to claim 1, characterized in that: The vehicle door window frame assembly includes: a vehicle door window frame sealing plate, a B-pillar trim, a glass front rail and a glass rear rail, wherein the vehicle door window frame sealing plate and the B-pillar trim are bonded to the vehicle door inner panel, and the glass front rail and the glass rear rail are screwed or riveted to the vehicle door inner panel.

3. The composite door system according to claim 1, characterized in that: The composite door system also includes a door anti-collision beam that is screwed or riveted to the door inner panel assembly.

4. The composite door system according to claim 1, characterized in that: The vehicle door outer panel bracket is connected to the vehicle door inner panel via mushroom nails and anti-theft screws.

5. The composite door system according to claim 1, characterized in that: The edges of the vehicle door outer panel and the vehicle door inner panel are sealed by sealing cotton.

6. The composite door system according to claim 1, characterized in that: The exterior surface of the vehicle door outer panel has false seams to achieve color separation and / or component separation.

7. A method for constructing a composite door system according to any one of claims 1 to 6, characterized in that: The following steps are involved: 1) The door window frame insert, the B-pillar trim insert, the door hinge area insert, the door water-cut window sill insert, and the door threshold insert are assembled and welded into an insert assembly; 2) providing a door inner panel, and integrally insert-molding the insert assembly and the door inner panel to form a door inner panel assembly; 3) Providing a vehicle door window frame assembly, including: a vehicle door window frame cover plate, a B-pillar trim plate, a glass front guide rail, and a glass rear guide rail, and connecting the vehicle door window frame assembly to the vehicle door inner panel assembly; 4) providing a door anti-collision beam, and screwing or riveting the door anti-collision beam to the door inner panel assembly; 5) providing a door outer panel bracket and a door outer panel, and bonding the door outer panel bracket to the inner side of the door outer panel; 6) providing a door outer water-cut sill beam with an integrated outer door handle metal reinforcement plate, and bonding it to the inner side of the upper end of the door outer panel to form a door outer panel assembly; and 7) The vehicle door outer panel assembly is connected to the vehicle door inner panel assembly by fasteners, and the edges of the vehicle door outer panel and the vehicle door inner panel are sealed by sealing cotton.

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