Rectangular tube girder and method of manufacturing the same

Abstract

The application discloses a rectangular tube main beam and a preparation method thereof, and comprises the following steps: laying and curing prepreg on a rectangular tube mold to obtain a rectangular tube blank; processing and punching the rectangular tube blank according to the position and size of metal parts to prepare a special-shaped tube body; laying and curing prepreg on a flat plate mold to obtain a flat plate blank; processing and punching the flat plate blank according to the position and size of metal parts to prepare metal part positioning holes; positioning the processed metal parts on the flat plate blank, then laying and curing prepreg on the metal parts and the flat plate blank to obtain a flat plate assembly containing the metal parts; and bonding and fixing the flat plate assembly and the special-shaped tube body to obtain the rectangular tube main beam. The preparation method can place multiple metal parts in a narrow inner cavity, effectively solves the problems of easy delamination and degumming existing in the current preparation method, reduces the difficulty of part forming, and reduces the labor and equipment costs.

Description

Technical Field

[0001] This invention belongs to the field of parts processing technology, specifically relating to a rectangular tube main beam and its preparation method. Background Technology

[0002] The existing composite material vehicle frame involves a rectangular tube main beam made of composite material. This main beam needs to be threadedly connected to other parts. Traditionally, a pre-embedded metal component is used as the base for the threads on the rectangular tube main beam, and then CNC-machined threaded holes on the pre-embedded metal component. However, due to the small internal size of the rectangular tube main beam, the large number of pre-embedded metal components within the cavity, and the complex shapes of these components, the internal space of the rectangular tube main beam becomes even more confined and irregular. During the part forming process, problems arise such as the inability to manually compact corners and the inability to package the product after curing. Furthermore, the heat generated during the machining of the threaded holes can cause problems such as product delamination, bag bursting, and degumming, affecting the main structural performance of the rectangular tube main beam and reducing its safety performance. Summary of the Invention

[0003] To address the aforementioned shortcomings in the existing technology, this invention provides a rectangular tube main beam and its manufacturing method. The manufacturing method enables the placement of multiple metal parts within a narrow internal cavity, effectively solving problems such as delamination and debonding that exist in existing manufacturing methods. This reduces the difficulty of part forming and significantly lowers labor and equipment costs.

[0004] To achieve the above objectives, the technical solution adopted by the present invention to solve its technical problem is as follows:

[0005] A method for fabricating a rectangular tube main beam includes the following steps:

[0006] (1) Lay the prepreg on the rectangular tube mold and cure it to obtain a rectangular tube blank. According to the position and size of the metal parts, process and drill holes in the rectangular tube blank to prepare the special-shaped tube body.

[0007] (2) The prepreg is laid on the flat mold and cured to obtain a flat blank; holes are drilled on the flat blank according to the position and size of the metal parts to prepare positioning holes for the metal parts.

[0008] (3) Position the processed metal parts on the flat blank, then lay the prepreg on the metal parts and the flat blank and cure it to obtain a flat assembly containing metal parts.

[0009] (4) The flat plate assembly is bonded and fixed to the shaped tube body to obtain the product.

[0010] Furthermore, the prepreg is a fiber prepreg.

[0011] Furthermore, the fiber prepreg includes one of carbon fiber prepreg, glass fiber prepreg, and aramid fiber prepreg.

[0012] Furthermore, CNC precision machining is used for drilling.

[0013] Furthermore, the curing method is hot-press curing molding, with a hot-pressing temperature of 90-150℃ and a pressure of 3-6 bar.

[0014] Furthermore, in step (2), the flat blank includes an upper flat blank and a lower flat blank.

[0015] A rectangular tubular main beam is manufactured using the method described above.

[0016] The beneficial effects of this invention are as follows:

[0017] 1. The rectangular tube main beam obtained by this invention serves as the main load-bearing structure. Its body wall thickness is uniform, the product performance is stable and reliable, and its service life can be improved.

[0018] 2. The metal parts used to prepare the rectangular tube main beam in this invention are pre-formed metal parts. The forming process is carried out separately, which is simple and convenient. It is also convenient to fix and process the metal parts during the forming process, which has the advantage of simple and convenient operation. In addition, the metal parts are processed with threaded holes before installation, which reduces the risk of delamination and degumming of the rectangular tube caused by processing heat, and improves the quality of the product.

[0019] 3. This invention fixes the prefabricated metal parts onto the flat blank, and then bonds the flat blank onto the prepared rectangular tube. This operation is simple and convenient, eliminates the need for post-processing tooling, greatly reduces the cost of labor and equipment, and significantly improves production efficiency.

[0020] 4. In this invention, the flat plate assembly containing metal parts is bonded to the inner wall of the rectangular tube over a large area, which greatly improves the torsional resistance and tensile strength of the metal parts, thereby increasing the structural safety of the entire product. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the preparation of a rectangular tube blank;

[0022] Figure 2 This is a schematic diagram of the upper flat plate blank structure;

[0023] Figure 3 This is a schematic diagram of the lower flat plate blank structure;

[0024] Figure 4 This is a schematic diagram showing the connection between the metal part and the upper flat plate blank.

[0025] Figure 5 This is a schematic diagram of the upper flat panel assembly structure;

[0026] Figure 6 This is a schematic diagram showing the connection between the metal part and the lower flat plate blank.

[0027] Figure 7 This is a schematic diagram of the lower flat panel assembly structure;

[0028] Figure 8 Schematic diagram of the cross-section of the rectangular tube main beam;

[0029] Figure 9 This is a schematic diagram of a rectangular tube main beam structure.

[0030] Reference numerals in the attached drawings: 1. Upper mold for rectangular tube; 2. Lower mold for rectangular tube; 3. Rectangular tube blank; 4. Shaped tube body; 5. Upper flat plate blank; 6. Lower flat plate blank; 7. Metal part; 8. Positioning hole for metal part; 9. Upper flat plate assembly; 10. Lower flat plate assembly; 11. Adhesive layer; 12. Main beam of rectangular tube. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention; that is, the described embodiments are merely some embodiments of the invention, and not all embodiments.

[0032] Therefore, the following detailed description of the embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0033] It should be noted that relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0034] The features and performance of the present invention will be further described in detail below with reference to the embodiments and accompanying drawings.

[0035] Example 1

[0036] A rectangular tubular main beam is manufactured by the following steps:

[0037] (1) The carbon fiber prepreg is laid in the upper mold 1 and the lower mold 2 of the rectangular tube, heated to 90°C, and pressure of 3 bar is applied. After curing, the rectangular tube blank 3 is obtained. According to the position and size of the metal part 7, the rectangular tube blank 3 is processed and drilled by CNC precision machining method to prepare the special tube body 4.

[0038] (2) The carbon fiber prepreg is laid on the upper plate mold and the lower plate mold respectively, heated to 90°C, and pressure of 3 bar is applied to solidify to obtain the upper plate blank 5 and the lower plate blank 6; according to the position and size of the metal part 7, CNC precision machining is used to process and drill holes on the upper plate blank 5 and the lower plate blank 6 to prepare the metal part positioning hole 8.

[0039] (3) Position the prefabricated threaded metal part 7 on the upper plate blank 5 and the lower plate blank 6, then lay the carbon fiber prepreg on the metal part 7 and the upper plate blank 5, heat it to 90°C, apply a pressure of 3 bar, so that an adhesive layer 11 is formed on the surface of the metal part 7 and the upper plate blank 5, and cure it to obtain the upper plate assembly 9 containing the metal part; at the same time, lay the carbon fiber prepreg on the metal part 7 and the lower plate blank 6, heat it to 90°C, apply a pressure of 3 bar, so that an adhesive layer 11 is formed on the surface of the metal part 7 and the lower plate blank 6, and cure it to obtain the lower plate assembly 10 containing the metal part 7.

[0040] (4) Align the metal parts 7 on the upper plate assembly 9 and the lower plate assembly 10 with the holes on the shaped tube body 4, and then bond and fix them to obtain the product.

[0041] Example 2

[0042] A rectangular tubular main beam is manufactured by the following steps:

[0043] (1) The glass fiber prepreg is laid in the upper mold 1 and the lower mold 2 of the rectangular tube, heated to 150°C, and pressure of 6 bar is applied. After curing, the rectangular tube blank 3 is obtained. According to the position and size of the metal part 7, the rectangular tube blank 3 is processed and punched by CNC precision machining method to prepare the special tube body 4.

[0044] (2) The glass fiber prepreg is laid on the upper plate mold and the lower plate mold respectively, heated to 150°C, and pressure of 6 bar is applied to solidify to obtain the upper plate blank 5 and the lower plate blank 6; according to the position and size of the metal part 7, CNC precision machining is used to process and drill holes on the upper plate blank 5 and the lower plate blank 6 to prepare the metal part positioning hole 8.

[0045] (3) Position the prefabricated threaded metal part 7 on the upper plate blank 5 and the lower plate blank 6, then lay the glass fiber prepreg on the metal part 7 and the upper plate blank 5, heat it to 150°C, apply a pressure of 6 bar, so that an adhesive layer 11 is formed on the surface of the metal part 7 and the upper plate blank 5, and cure it to obtain the upper plate assembly 9 containing the metal part; at the same time, lay the glass fiber prepreg on the metal part 7 and the lower plate blank 6, heat it to 150°C, apply a pressure of 6 bar, so that an adhesive layer 11 is formed on the surface of the metal part 7 and the lower plate blank 6, and cure it to obtain the lower plate assembly 10 containing the metal part 7.

[0046] (4) Align the metal parts 7 on the upper plate assembly 9 and the lower plate assembly 10 with the holes on the shaped tube body 4, and then bond and fix them to obtain the product.

[0047] Example 3

[0048] A rectangular tubular main beam is manufactured by the following steps:

[0049] (1) Lay aramid fiber prepreg in rectangular tube upper mold 1 and rectangular tube lower mold 2, heat to 120°C, apply 4 bar pressure, and solidify to obtain rectangular tube blank 3. According to the position and size of metal part 7, use CNC precision machining method to process and punch holes in rectangular tube blank 3 to prepare special tube body 4.

[0050] (2) The aramid fiber prepreg is laid on the upper plate mold and the lower plate mold respectively, heated to 120°C, and pressure of 4 bar is applied to solidify to obtain the upper plate blank 5 and the lower plate blank 6; according to the position and size of the metal part 7, CNC precision machining is used to process and drill holes on the upper plate blank 5 and the lower plate blank 6 to prepare the metal part positioning hole 8.

[0051] (3) Position the prefabricated threaded metal part 7 on the upper plate blank 5 and the lower plate blank 6, then lay the aramid fiber prepreg on the metal part 7 and the upper plate blank 5, heat it to 120°C, apply a pressure of 4 bar, so that an adhesive layer 11 is formed on the surface of the metal part 7 and the upper plate blank 5, and cure it to obtain the upper plate assembly 9 containing the metal part; at the same time, lay the aramid fiber prepreg on the metal part 7 and the lower plate blank 6, heat it to 120°C, apply a pressure of 4 bar, so that an adhesive layer 11 is formed on the surface of the metal part 7 and the lower plate blank 6, and cure it to obtain the lower plate assembly 10 containing the metal part 7.

[0052] (4) Align the metal parts 7 on the upper plate assembly 9 and the lower plate assembly 10 with the holes on the shaped tube body 4, and then bond and fix them to obtain the product.

[0053] The rectangular tube main beam prepared by the method in this application has a uniform wall thickness. The flat blank with metal parts is fixed to the rectangular tube by integral bonding, which can increase the bonding area between the flat blank and the rectangular tube, thereby improving the bonding strength. This ensures that the flat blank does not fall off during use, making the product structurally safer and greatly improving the product quality and service life.

Claims

1. A method for preparing a rectangular tube main beam, characterized in that, Includes the following steps: (1) Lay the prepreg on the rectangular tube mold and cure it to obtain a rectangular tube blank. According to the position and size of the metal parts, process and drill holes in the rectangular tube blank to prepare the special-shaped tube body. (2) The prepreg is laid on the flat mold and cured to obtain a flat blank; holes are drilled on the flat blank according to the position and size of the metal parts to prepare positioning holes for the metal parts; (3) Position the processed metal parts on the flat blank, then lay the prepreg on the embedded metal parts and the flat blank and cure it to obtain a flat assembly containing metal parts. (4) The flat plate assembly is bonded and fixed to the shaped tube body to obtain the product.

2. The method for preparing a rectangular tube main beam according to claim 1, characterized in that, The prepreg is a fiber prepreg.

3. The method for preparing a rectangular tube main beam according to claim 2, characterized in that, The fiber prepreg includes one of carbon fiber prepreg, glass fiber prepreg, and aramid fiber prepreg.

4. The method for preparing a rectangular tube main beam according to claim 1, characterized in that, The holes are drilled using CNC precision machining.

5. The method for preparing a rectangular tube main beam according to claim 1, characterized in that, The curing method is hot-press curing molding, with a hot-pressing temperature of 90-150℃ and a pressure of 3-6 bar.

6. The method for preparing a rectangular tube main beam according to claim 1, characterized in that, In step (2), the flat blank includes an upper flat blank and a lower flat blank.

7. A rectangular tubular main beam, characterized in that, It is prepared by the method described in any one of claims 1-6.

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