Special prototype vehicle door and manufacturing method thereof

Abstract

The present invention discloses a method for manufacturing a special prototype vehicle door, comprising steps of preparing basic door components, preparing a carbon fiber composite mold, preparing a carbon fiber composite door and window frame, preparing a contoured filler, and assembling the door components. The present invention also discloses a special prototype vehicle door, comprising basic door components, a carbon fiber composite door and window frame, contoured fillers, a door handle and lock mechanism, glass, a sealing strip, and an exterior cover. The carbon fiber composite door and window frame is formed using a carbon fiber composite mold and basic door components through a hand-paste molding process using carbon fiber cloth and epoxy resin. The carbon fiber composite door and window frame is interlocked and fixed to the basic door components, and the contoured fillers are fixed to the carbon fiber composite door and window frame. The remaining door components are then assembled to form a complete door shape.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile manufacturing, and more particularly to the manufacturing technology of automobile test samples. Background Art

[0002] When manufacturing special prototype vehicles for defogger and defrost tests, it's necessary to create front doors with project-specific door frames to ensure the glass installed in the door frames is consistent with the project-specific state, thus ensuring the accuracy of the defogger and defrost tests. There are currently two main methods commonly used to manufacture special prototype vehicle doors: the first involves creating expensive sheet metal stamping dies based on the new project-specific door sheet metal part data. This die is then used to stamp out the complete door inner and outer panels, along with the reinforcement plate. Multiple sets of fixtures are then manufactured to weld and hem all the door sheet metal in multiple steps, completing the sheet metal door part fabrication. The second method involves creating only the project-specific door and window frame sheet metal parts with stamping dies. The section below the door and window frame is cut from a similar vehicle of the same class, removing the frame. A welding fixture is then designed and manufactured to weld the new project-specific door and window frame sheet metal die to the section below the original base vehicle's door and window frame. These two traditional manufacturing methods can ensure the accuracy (±1.5mm) and strength of the door, but both require the manufacture of multiple sheet metal stamping dies, the production of welding fixtures and welding, and the long production cycle and high production costs of parts. In terms of the door manufacturing process, it is also possible to use carbon fiber composite materials to make the inner and outer panels of the door. That is, multiple sets of molds are used to make the inner and outer panels and the reinforcements between the door panels, and then bite and mill to ensure that the accuracy of the parts is within the tolerance range. However, this process uses a large amount of carbon fiber composite materials, has many steps, and a complex manufacturing process. Due to the high price of carbon fiber, the cost is very high, and it is generally not used for special prototypes for experimental purposes. Summary of the Invention

[0003] According to one embodiment of the present invention, a method for manufacturing a special prototype vehicle door is provided, comprising the following steps:

[0004] a step of preparing a basic door component, wherein the basic door component is formed by cutting a door of an existing vehicle model;

[0005] a carbon fiber composite material mold preparation step, designing and manufacturing a carbon fiber composite material mold according to the parameters of the basic door component and the door and window frame parameters of the prototype vehicle door;

[0006] a step of preparing a carbon fiber composite door and window frame, using the carbon fiber composite mold and the basic vehicle door component to form the carbon fiber composite door and window frame by hand-paste molding of carbon fiber cloth and epoxy resin, wherein the carbon fiber composite door and window frame is engaged with the basic vehicle door component;

[0007] a step of preparing a contoured filler, milling the filler material according to the shape of the carbon fiber composite door and window frame to prepare a contoured filler that matches the shape of the carbon fiber composite door and window frame, and fixing the contoured filler to the carbon fiber composite door and window frame;

[0008] The steps for assembling the door components include preparing the exterior cover, installing the glass, sealing strips and exterior cover, wherein the glass and sealing strips are installed on the contoured filler, and the exterior cover is installed on the basic door components to form a complete door shape.

[0009] In one embodiment, the basic door component preparation step includes:

[0010] Select an existing model of the same series or with a similar appearance as the sample vehicle, and obtain the doors of the existing model;

[0011] The vehicle door is cut to remove the door window frame and part of the door outer panel and door inner panel. The lower half of the vehicle door, the remaining door inner panel and door outer panel retained after cutting form the basic vehicle door component.

[0012] In one embodiment, the carbon fiber composite material mold is used as a bite mold for a carbon fiber composite material door and window frame and a basic vehicle door component. The carbon fiber composite material mold has a bite line, which marks the bite area. Within the bite area, the carbon fiber composite material wraps the door inner panel of the basic vehicle door component to sandwich the sheet metal of the door inner panel between the carbon fiber composite material.

[0013] In one embodiment, the width of the bite area is not less than 40 mm and the bite area covers the position of the reinforcement plate on the basic door component, and the carbon fiber composite material mold is formed by polyurethane milling, wherein the carbon fiber composite material mold has only a single-sided profile.

[0014] In one embodiment, the steps of preparing the carbon fiber composite door and window frames include:

[0015] Applying a release agent on a carbon fiber composite material mold, laying carbon fiber cloth, and brushing epoxy resin to form a carbon fiber composite material;

[0016] Before the carbon fiber composite material is cured, the basic door component is embedded in a carbon fiber composite material mold and clamped;

[0017] In the bite area, carbon fiber cloth is laid on the basic door component and epoxy resin is applied;

[0018] Laying carbon fiber cloth and applying epoxy resin in the area corresponding to the door and window frames and the bite area in the carbon fiber composite material mold so that the carbon fiber composite material fills and covers the area corresponding to the door and window frames and the bite area;

[0019] After the carbon fiber composite material is cured, the carbon fiber composite material mold is removed to obtain a carbon fiber composite material door and window frame that engages with the basic vehicle door component.

[0020] In one embodiment, the contoured filler is made of polyurethane. According to the outer molding surface of the carbon fiber composite door and window frame, the polyurethane material is milled with the smooth surface of the carbon fiber composite door and window frame offset 4 mm inward as the reference plane. During milling, a processing allowance of not less than 5 mm is left for the polyurethane material in the normal direction of the outer molding of the door. The polyurethane contoured filler is obtained by milling, and the polyurethane contoured filler and the carbon fiber composite door and window frame are bonded together using epoxy resin, and the epoxy resin is waited for to solidify.

[0021] In one embodiment, the step of preparing the contour filler further comprises:

[0022] The outer surface of the polyurethane contoured filler is milled according to the door and window frame parameters of the prototype vehicle door to form the mounting surface for the glass and sealing strips, and the mounting holes for the exterior cover and interior parts are milled out.

[0023] In one embodiment, the exterior cover plate is made of ABS material, and the shape of the exterior cover plate matches the door outer panel portion cut off from the basic door component. The exterior cover plate is installed on the basic door component and spliced ​​with the remaining door outer panel to form a complete door outer panel shape.

[0024] According to one embodiment of the present invention, a special prototype vehicle door is provided, comprising: a basic door component, a carbon fiber composite door and window frame, a contoured filler, a door handle and lock mechanism, glass, a sealing strip, and an exterior cover;

[0025] The basic door component is formed by cutting the door of an existing vehicle model. The carbon fiber composite door and window frame is formed by hand-paste molding of carbon fiber cloth and epoxy resin using a carbon fiber composite mold and the basic door component. The carbon fiber composite door and window frame is fixed to the basic door component by bite. The shape of the contoured filler matches the shape of the carbon fiber composite door and window frame. The contoured filler is fixed to the carbon fiber composite door and window frame. The door handle and lock mechanism, glass and sealing strip are installed on the contoured filler. The exterior cover is installed on the basic door component to form a complete door shape.

[0026] In one embodiment, the carbon fiber composite material is formed of carbon fiber cloth and epoxy resin; the contoured filler is made of polyurethane and is fixed to the carbon fiber composite door and window frame by epoxy resin; and the exterior cover is made of ABS.

[0027] The manufacturing method of the special prototype vehicle door of the present invention does not require the production of welding fixtures, saving a lot of mold and fixture production costs. A composite process of carbon fiber composite materials and door sheet metal is used, and polyurethane materials are used to strengthen the carbon fiber composite materials, which effectively solves the problem of insufficient strength and stiffness of carbon fiber composite materials perpendicular to the fiber direction in such applications. The carbon fiber composite material forming mold not only plays the role of carbon fiber composite material molding, but also plays the role of positioning and biting of vehicle door sheet metal, and the role of counter-forming mold when milling the exterior shape of the vehicle door, so that one mold can be used for multiple purposes. When milling the exterior shape, the door and window frames and door sheet metal are already bitten, and the integrated milling precision is high. Compared with other alternative methods, this method has a significantly shortened manufacturing cycle and a significantly reduced cost, and can well meet the loading needs of special prototype vehicles such as defogger and defroster vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A flow chart of a method for manufacturing a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0029] Figure 2 A structural diagram of basic door components of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0030] Figure 3 A structural diagram of a carbon fiber composite door and window frame of a basic door component of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0031] Figure 4 A schematic diagram of the engaging portion of a basic door component and a carbon fiber composite door and window frame of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0032] Figure 5 A schematic cross-sectional view of the engaging portion of a basic door component and a carbon fiber composite door and window frame of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0033] Figure 6 A schematic structural diagram of a carbon fiber composite door and window frame and contoured filler of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0034] Figure 7 A cross-sectional schematic diagram of a carbon fiber composite door and window frame and contoured filler of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0035] Figure 8 A structural diagram of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0036] Figure 9 An exploded structural diagram of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0037] Figure 10 A cross-sectional view of a special prototype vehicle door according to an embodiment of the present invention is disclosed.

[0038] Figure 11 A schematic diagram of the manufacturing process of a special prototype vehicle door according to an embodiment of the present invention is disclosed. DETAILED DESCRIPTION

[0039] Figure 1 A flow chart of a method for manufacturing a special prototype vehicle door according to an embodiment of the present invention is disclosed. Figure 1 As shown, the manufacturing method of the special prototype vehicle door includes the following steps:

[0040] S101, basic door component preparation step. The basic door component is formed by cutting the door of an existing vehicle model. In one embodiment, the basic door component preparation process is as follows: first, an existing vehicle model of the same series or with a similar appearance as the prototype vehicle is selected, and the door of the existing vehicle model is obtained. The door is then cut to remove the door and window frame and part of the door outer panel and door inner panel. The lower half of the door, the remaining door inner panel and door outer panel retained after cutting form the basic door component. In a specific implementation, a vehicle model of the same series or with a similar appearance as the target vehicle model is selected as the base vehicle, and the door inner and outer panels are cut, starting from the lower section of the upper door and window frame, and the door and window frame part is removed, and part of the door outer panel is removed at the same time. This can minimize the manufacturing scope of new parts, while using the lower section of the door frame to ensure the accuracy of the door hinge and the strength of the door body. Figure 2 The structural diagram of the basic door components obtained by cutting the doors of existing models is revealed.

[0041] S102: Preparation of a carbon fiber composite mold. A carbon fiber composite mold is designed and manufactured based on the parameters of the base door component and the door and window frame parameters of the prototype vehicle door. This carbon fiber composite mold serves as the interlocking mold for the carbon fiber composite door and window frame and the base door component. The carbon fiber composite mold has an interlocking line that demarcates the interlocking area. Within this interlocking area, the carbon fiber composite wraps around the door inner panel of the base door component, sandwiching the sheet metal of the door inner panel between the carbon fiber composite materials. In one embodiment, the width of the interlocking area A is no less than 40 mm and covers the location of the reinforcement plate on the base door component. The carbon fiber composite mold is milled from polyurethane and has only a single-sided profile. In one specific implementation, the carbon fiber composite mold is designed based on the door and window frame data of the new project status as input. This mold can simultaneously interlock the carbon fiber composite door and window frame with the retained sheet metal door panel. The mold has an interlocking line, which must be located on the surface of the retained sheet metal portion of the door inner panel. It should be noted that when the carbon fiber composite material is subsequently manufactured, the bite line should ensure the effective width of the bite area and ensure that the carbon fiber composite material 501 can sandwich the sheet metal material 502 retained by the basic door component. Figure 4 and Figure 5 As shown. Figure 4 A schematic diagram showing the interface between the basic door component and the carbon fiber composite door and window frame. Figure 5 A schematic cross-section of the interface between the base door component and the carbon fiber composite door and window frame is revealed. The upper portion of the interface line represents the new part's contour, consistent with the new design. The carbon fiber composite door and window frame will be cut along this line later, ensuring a perfect fit when the base vehicle sheet metal is placed into the mold. Subsequently, the carbon fiber composite mold is milled out of polyurethane, typically low-density polyurethane. This mold has a single-sided profile, retaining only the inner surface of the door and window frame. This reduces mold production costs by half compared to molds that require milling of male and female dies. This also cuts the cost of using the carbon fiber composite material in half.

[0042] S103: Preparation of carbon fiber composite door and window frames. Using a carbon fiber composite mold and a base door component, a carbon fiber composite door and window frame is formed by hand-laying carbon fiber cloth and epoxy resin. The carbon fiber composite door and window frame is interlocked with the base door component. In one embodiment, the preparation of the carbon fiber composite door and window frame comprises: applying a release agent to the carbon fiber composite mold, laying carbon fiber cloth, and applying epoxy resin to form the carbon fiber composite. Before the carbon fiber composite is cured, the base door component is inserted into the carbon fiber composite mold and clamped. In the interlocking area, carbon fiber cloth is laid on the base door component and epoxy resin is applied. Carbon fiber cloth is laid and epoxy resin is applied to the area corresponding to the door and window frame and the interlocking area within the carbon fiber composite mold, so that the carbon fiber composite fills and covers the area corresponding to the door and window frame and the interlocking area. After the carbon fiber composite is cured, the carbon fiber composite mold is removed to obtain a carbon fiber composite door and window frame interlocked with the base door component. Figure 3 The structural diagram of the manufactured carbon fiber composite door and window frame is revealed. In a specific implementation, the preparation process of the carbon fiber composite door and window frame is as follows: a release agent is applied to the carbon fiber composite mold, carbon fiber cloth is laid in sequence, and epoxy resin is brushed on to form a carbon fiber composite material. At this time, the thickness of the carbon fiber composite material is 1mm. Before the carbon fiber composite material is cured, the cut base door sheet metal is embedded in the mold and clamped with a chuck. Subsequently, carbon fiber cloth is laid in sequence on the upper surface of the door sheet metal (occlusal area) and epoxy resin is brushed on so that the carbon fiber cloth and epoxy resin completely cover the new shape area and the occlusal area. In this way, after the carbon fiber composite material is cured, the sheet metal part can be sandwiched in the middle. It is necessary to ensure that the occlusal area is not less than 40mm wide and has good rigidity. The occlusal area must include the position of the reinforcement plate. This can ensure that the carbon fiber composite material has good strength after the occlusion. After the carbon fiber composite material is cured, a door part with a smooth inner side can be obtained.

[0043] S104, a contoured filler preparation step. The filler material is milled according to the shape of the carbon fiber composite door and window frame to prepare a contoured filler that matches the shape of the carbon fiber composite door and window frame, and the contoured filler is fixed to the carbon fiber composite door and window frame. In one embodiment, the contoured filler 601 is made of polyurethane. Based on the outer contoured surface of the carbon fiber composite door and window frame 602, the polyurethane material is milled with a 4mm inward offset of the smooth surface of the carbon fiber composite door and window frame 602 as a reference plane. During milling, the polyurethane material is left with a processing allowance of not less than 5mm in the normal direction of the outer contour of the door. The polyurethane contoured filler is milled to obtain the polyurethane contoured filler. The polyurethane contoured filler and the carbon fiber composite door and window frame are bonded together using epoxy resin 603, and the epoxy resin is allowed to cure. In one embodiment, the contoured filler preparation step further includes: milling the outer surface of the polyurethane contoured filler according to the door and window frame parameters of the prototype vehicle door to form a mounting surface for the glass and the sealing strip, and milling out mounting holes for the exterior cover plate and mounting holes for interior trim parts. Figure 6 The structural diagram of carbon fiber composite door and window frames and contoured fillers is revealed. Figure 6 The carbon fiber composite door and window frame 602 has been snap-fitted to the base door component 604 . Figure 7 A schematic cross-section of a carbon fiber composite door and window frame and contoured filler is revealed. Figure 6 and Figure 7 As shown, in a specific implementation, the cross-section of the carbon fiber material of the prepared carbon fiber composite door and window frame is in an open state, and the strength is still not enough to meet the needs of special prototype vehicles. It is necessary to add a polyurethane profile filler (also called a wood core substitute) inside the carbon fiber material. The process of making the polyurethane profile filler is as follows: First, according to the smooth surface of the molded carbon fiber composite door and window frame, it is offset inward by 4mm, and the polyurethane material is milled according to the outer molding surface of the door and window frame and the inner molding surface of the window frame with a 4mm offset from the smooth surface. The polyurethane material needs to have a processing allowance in the normal direction of the outer molding of the door, which is not less than 5mm. The positional relationship between the polyurethane profile filler and the carbon fiber composite door frame is shown as follows. Figure 7 Then use epoxy resin to bond the polyurethane profile filler and the carbon fiber composite door and window frame together. After the epoxy resin is cured, mill the outer surface of the polyurethane profile filler according to the outer shape of the door and window frame (the outer surface facing outwards in the outer shape of the door, Figure 7 The middle mark is milling surface B), the installation surface of the glass and sealing strip, and at the same time, the installation holes of the exterior cover plate and the installation holes of the interior parts are milled.

[0044] S105: Door component assembly step. Prepare the exterior cover panel, install the glass, sealing strip, and exterior cover panel. The glass and sealing strip are mounted on the contoured filler, and the exterior cover panel is mounted on the base door component to form a complete door shape. In one embodiment, the exterior cover panel is made of ABS. The shape of the exterior cover panel matches the door outer panel portion removed from the base door component. The exterior cover panel is installed on the base door component and spliced ​​with the remaining door outer panel to form a complete door outer panel shape. Figure 8 The structural diagram of a special prototype car door according to an embodiment of the present invention is disclosed. In a specific implementation, the door handle and lock mechanism, sealing strips and glass are installed when the door parts are assembled, and the glass is fixed to the polyurethane contour filler using a glass pressing plate. Finally, a cover plate is installed on the part where the door outer panel sheet metal is cut away. The exterior cover plate is usually made of ABS material. The design of the cover plate ensures that the new door and window frame and the basic door outer panel can match well, ensuring the beauty of the outer shape of the door panel. The effect after the door body is completed is as follows Figure 8 shown.

[0045] According to one embodiment of the present invention, a special prototype vehicle door is also provided. Figure 9 and Figure 10 The structure of the door of this special prototype is revealed, Figure 9 The exploded structure diagram of the special prototype car's door is revealed. Figure 10 A cross-section of the doors of the special prototype vehicle is revealed. Figure 9 and Figure 10 As shown, the door of this special prototype vehicle includes: a basic door component 2, a carbon fiber composite door and window frame 1, a contoured filler 3, a door handle and lock mechanism 4, a glass 6, a sealing strip 5 and an exterior cover 8. The basic door component 2 is formed by cutting the door of an existing vehicle model, removing the door and window frame and part of the door outer panel and door inner panel. The lower half of the door retained after cutting, the remaining door inner panel 21 and the door outer panel 22 form the basic door component 2. The carbon fiber composite door and window frame 1 is formed by hand-paste molding of carbon fiber cloth and epoxy resin using a carbon fiber composite mold 9 and the basic door component 2. The specific steps of the process of molding the carbon fiber composite door and window frame 1 using the carbon fiber composite mold 9 can refer to the aforementioned steps S102 and S103. Figure 11 Further disclosed is a schematic diagram of the manufacturing process of a special prototype vehicle door according to an embodiment of the present invention. Figure 11The carbon fiber composite mold is shown in the following state: a release agent has been applied, carbon fiber cloth has been laid, and epoxy resin has been applied to form the carbon fiber composite. Before the carbon fiber composite cures, a base door component 2 is inserted into the carbon fiber composite mold 9 and clamped using a pressure plate 10. Carbon fiber cloth is then laid on the base door component in the mating area and epoxy resin is applied. Carbon fiber cloth is then laid and epoxy resin is applied in the areas corresponding to the door and window frames and the mating area within the carbon fiber composite mold, ensuring that the carbon fiber composite fills and covers the areas corresponding to the door and window frames and the mating area. After the carbon fiber composite cures, the carbon fiber composite mold is removed, and the carbon fiber composite door and window frames are now mated and secured to the base door component. The contoured filler 3 is designed to match the shape of the carbon fiber composite door and window frame 1 and is secured to the carbon fiber composite door and window frame 1. Next, various door components are installed, including the door handle and lock mechanism 4, glass 6, sealing strip 5, and exterior trim panel 8. The door handle and lock mechanism 4 and sealing strip 5 are mounted on the contoured filler 3. The glass 6 is attached to the contoured filler 3 via a glass pressure plate 7. The exterior cover plate 8 is mounted on the base door component 2. More specifically, it is attached to the sheet metal of the door outer panel 22. The design of the exterior cover plate 8 ensures a perfect match between the newly designed door and window frame and the base door outer panel, ensuring the aesthetically pleasing exterior styling of the door panel and forming a complete door design. In one embodiment, the carbon fiber composite material is formed from carbon fiber cloth and epoxy resin, and the contoured filler is made of polyurethane and fixed to the carbon fiber composite door and window frame via epoxy resin. The exterior cover plate is made of ABS.

[0046] The manufacturing method of the special prototype vehicle door of the present invention does not require the production of welding fixtures, saving a lot of mold and fixture production costs. A composite process of carbon fiber composite materials and door sheet metal is used, and polyurethane materials are used to strengthen the carbon fiber composite materials, which effectively solves the problem of insufficient strength and stiffness of carbon fiber composite materials perpendicular to the fiber direction in such applications. The carbon fiber composite material forming mold not only plays the role of carbon fiber composite material molding, but also plays the role of positioning and biting of vehicle door sheet metal, and the role of counter-forming mold when milling the exterior shape of the vehicle door, so that one mold can be used for multiple purposes. When milling the exterior shape, the door and window frames and door sheet metal are already bitten, and the integrated milling precision is high. Compared with other alternative methods, this method has a significantly shortened manufacturing cycle and a significantly reduced cost, and can well meet the loading needs of special prototype vehicles such as defogger and defroster vehicles.

[0047] As described above, the manufacturing method for the special prototype vehicle door of the present invention has the following beneficial effects: Through the above method, a carbon fiber composite door and window frame, cut door sheet metal, and a reinforcing polyurethane contoured filler are highly strongly bonded together on a single, low-cost mold. This carbon fiber composite molding mold not only serves as the concave mold for the carbon fiber composite molding process but also functions as a snap-fit ​​fixture and machining counter-form. This method not only meets the data requirements for the door and window frames of a new project, but also eliminates the need for expensive sheet metal stamping dies, sheet metal welding fixtures, and sheet metal welding, saving significant time and money, potentially saving nearly one million yuan in manufacturing costs alone. Furthermore, this method utilizes doors from the same series or similarly designed models as a base, minimizing the manufacturing footprint and further reducing manufacturing costs. Using a polyurethane wood substitute material to reinforce a single-sided carbon fiber composite door and window frame eliminates the expense of fabricating separate door and window frame outer panels, ensuring the required strength. Subsequent milling of the polyurethane substitute wood ensures precise installation of the door glass and a more aesthetically pleasing exterior finish. The removable ABS sheet metal cover on the door's outer panel also leaves ample space for later installation of door interior components. This demonstrates that the present invention's method for manufacturing a special prototype vehicle door addresses the high costs and long production cycles associated with existing technologies. Compared to existing technologies, this method significantly reduces manufacturing time while lowering costs.

[0048] It should also be noted that the embodiments listed above are only specific embodiments of the present invention. Obviously, the present invention is not limited to the above embodiments, and similar changes or modifications made therewith are directly derived from the contents disclosed by those skilled in the art or can be easily associated with them, and should all fall within the scope of protection of the present invention. The above embodiments are provided to those familiar with the art to implement or use the present invention, and those familiar with the art can make various modifications or changes to the above embodiments without departing from the inventive concept of the present invention. Therefore, the scope of protection of the present invention is not limited by the above embodiments, but should be the maximum scope of the innovative features mentioned in the claims.

Claims

1. A method for manufacturing a special prototype vehicle door, characterized in that: include: a step of preparing a basic door component, wherein the basic door component is formed by cutting a door of an existing vehicle model; a carbon fiber composite material mold preparation step, designing and manufacturing a carbon fiber composite material mold according to the parameters of the basic door component and the door and window frame parameters of the prototype vehicle door; A step of preparing a carbon fiber composite door and window frame, comprising: utilizing the carbon fiber composite mold and the basic door component to form a carbon fiber composite door and window frame by hand-paste molding of carbon fiber cloth and epoxy resin, wherein the carbon fiber composite door and window frame is engaged with the basic door component, and the carbon fiber composite mold is used as an engagement mold for the carbon fiber composite door and window frame and the basic door component, wherein the carbon fiber composite mold has an engagement line, wherein the engagement line marks an engagement area, wherein the carbon fiber composite wraps the door inner panel of the basic door component so as to sandwich the sheet metal of the door inner panel between the carbon fiber composite, wherein the engagement area is not less than 40 mm and the engagement area covers the position of the reinforcement plate on the basic door component, and wherein the carbon fiber composite mold is formed by milling of polyurethane, wherein the carbon fiber composite mold has only a single-sided profile; a step of preparing a contoured filler, milling the filler material according to the shape of the carbon fiber composite door and window frame to prepare a contoured filler that matches the shape of the carbon fiber composite door and window frame, and fixing the contoured filler to the carbon fiber composite door and window frame; The steps for assembling the door components include preparing the exterior cover, installing the glass, sealing strips and exterior cover, wherein the glass and sealing strips are installed on the contoured filler, and the exterior cover is installed on the basic door components to form a complete door shape.

2. The method for manufacturing a special prototype vehicle door according to claim 1, wherein: The basic door component preparation steps include: Select an existing model in the same series as the sample vehicle and obtain the doors of the existing model; The vehicle door is cut to remove the door window frame and part of the door outer panel and door inner panel. The lower half of the vehicle door, the remaining door inner panel and door outer panel retained after cutting form the basic vehicle door component.

3. The method for manufacturing a special prototype vehicle door according to claim 1, wherein: The steps of preparing the carbon fiber composite door and window frame include: Applying a release agent on a carbon fiber composite material mold, laying carbon fiber cloth, and brushing epoxy resin to form a carbon fiber composite material; Before the carbon fiber composite material is cured, the basic door component is embedded in a carbon fiber composite material mold and clamped; In the bite area, carbon fiber cloth is laid on the basic door component and epoxy resin is applied; Laying carbon fiber cloth and applying epoxy resin in the area corresponding to the door and window frames and the bite area in the carbon fiber composite material mold so that the carbon fiber composite material fills and covers the area corresponding to the door and window frames and the bite area; After the carbon fiber composite material is cured, the carbon fiber composite material mold is removed to obtain a carbon fiber composite material door and window frame that engages with the basic vehicle door component.

4. The method for manufacturing a special prototype vehicle door according to claim 1, wherein: The contoured filler is made of polyurethane. According to the outer shaping surface of the carbon fiber composite door and window frame, the polyurethane material is milled with the smooth surface of the carbon fiber composite door and window frame offset 4 mm inward as the reference plane. During milling, a processing allowance of no less than 5 mm is left for the polyurethane material in the normal direction of the outer shaping of the door. The polyurethane contoured filler is obtained by milling, and the polyurethane contoured filler and the carbon fiber composite door and window frame are bonded together using epoxy resin, and the epoxy resin is left to cure.

5. The method for manufacturing a special prototype vehicle door according to claim 1, wherein: The step of preparing the contour filler further comprises: The outer surface of the polyurethane contoured filler is milled according to the door and window frame parameters of the prototype vehicle door to form the mounting surface for the glass and sealing strips, and the mounting holes for the exterior cover and interior parts are milled out.

6. The method for manufacturing a special prototype vehicle door according to claim 2, wherein: The exterior cover plate is made of ABS material, and the shape of the exterior cover plate matches the door outer panel portion cut off from the basic door component. The exterior cover plate is installed on the basic door component and spliced ​​with the remaining door outer panel to form a complete door outer panel shape.

7. A special prototype car door, characterized in that: include: Basic door components, carbon fiber composite door and window frames, contoured fillers, door handles and lock mechanisms, glass, weatherstripping, and exterior trim panels; The basic door component is formed by cutting the door of an existing vehicle model. The carbon fiber composite door and window frame is formed by hand-paste molding of carbon fiber cloth and epoxy resin using a carbon fiber composite mold and the basic door component. The carbon fiber composite door and window frame is fixed to the basic door component by bite. The shape of the contoured filler matches the shape of the carbon fiber composite door and window frame. The contoured filler is fixed to the carbon fiber composite door and window frame. The door handle and lock mechanism, glass and sealing strip are installed on the contoured filler. The exterior cover is installed on the basic door component to form a complete door shape.

8. The special prototype vehicle door according to claim 7, characterized in that: The carbon fiber composite material is formed of carbon fiber cloth and epoxy resin; The contoured filler is made of polyurethane and is fixed to the carbon fiber composite door and window frames by epoxy resin; The exterior cover plate is made of ABS material.

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