A modular mold for forming a composite bus body and a method for forming a bus body

Abstract

The application provides a modular die for forming a composite bus body and a bus body forming method, which are suitable for forming bus bodies of different vehicle types sharing a gantry frame, and comprise a common die and multiple feature dies; the outer surface of the common die is a simple drawing surface of the inner surface of the bus gantry frame; each feature die is suitable for forming a feature structure of a bus body of a vehicle type, and each feature die comprises multiple feature dies; the feature dies are located at positions on the common die corresponding to the feature structures of the bus bodies, and are detachably connected to the common die; and the outer surface of the feature dies is used for forming the inner surface of the feature structure of the bus body. The modular die adopts a common die and multiple feature dies, and can realize the production of composite bus bodies of different vehicle types sharing a gantry frame by adjusting the multiple feature dies, so that the vehicle type can be changed without additional cost, and the period and cost of multiple designs and multiple die opening are saved.

Description

Technical Field

[0001] This invention belongs to the field of composite material technology, specifically relating to a modular mold for forming composite bus bodies and a body forming method. Background Technology

[0002] With the gradual implementation of the "dual carbon" policy, the state and industry have put forward higher requirements for the lightweight transformation and upgrading of automobiles, especially large public buses, as well as energy conservation, emission reduction, and emission reduction. Traditional metal bus bodies are limited by key factors such as heavy weight, poor corrosion resistance, and poor environmental friendliness of welding and heat treatment processes. Therefore, the structural materials are gradually shifting from traditional metal materials to carbon fiber composite materials. Chinese patent document CN207416735U discloses a composite material bus body side panel, including a side panel body, connecting profiles, and an outer side panel trim. The side panel body is a foam sandwich structure, with both the inner and outer skins of the foam sandwich structure being made of glass fiber fabric or carbon fiber fabric. Foam is placed between the inner and outer skins, and the foam sandwich is integrally molded. Connecting profiles are installed on the outer skin to connect with the outer side panel trim. This bus body side panel is made of a composite material with glass fiber and its fabric as reinforcement, using the inner surface of the bus body as the mold surface. The process of preparing bus bodies from carbon fiber composite materials is usually as follows: the reinforcing material is laid onto a composite mold designed according to the structural dimensions of the bus body, the composite material is formed by vacuum injection of resin or other molding methods, then cured, demolded, and the composite bus body product is obtained.

[0003] However, current composite molds used for fabricating composite bus bodies are typically monolithic, meaning the left side panel, right side panel, and roof are each formed using a separate monolithic mold. After each part is formed, the left side panel, right side panel, and roof are connected to form the complete bus body. This type of mold can only be used to form products of one size specification. Once the mold design is determined, the size specification is fixed and cannot be adapted to user requirements. Facing the bus industry's demands for small-batch, multi-variety, and diversified markets, new molds must be continuously designed and developed. A family of vehicles sharing the same gantry frame typically includes several models, and different models differ in the number of steps, wheelbase, and the size and position of doors and windows. A fixed mold can only be used for one model and cannot adapt to the changing requirements of a family of vehicles. However, developing a separate mold for each model is neither economical nor practical, leading to increased product costs, longer production cycles, and wasted space, which to some extent hinders the promotion of composite new energy buses. Therefore, a composite material bus mold is needed that can meet the production needs of a family of vehicles sharing the same gantry frame, achieving multi-purpose functionality with a single mold. Summary of the Invention

[0004] The technical problem solved by this invention is to provide a modular mold and a method for molding composite bus bodies. The modular mold adopts a set of general molds plus multiple sets of feature molds. By adjusting the multiple sets of feature molds and positioning them with the general mold, the production of composite body of different models with a common gantry frame can be realized. There is no additional cost for changing the model style. At the same time, it saves the cycle and cost of multiple design and mold opening. While reducing costs and increasing efficiency, it can quickly respond to market demand and complete production, effectively improving market competitiveness.

[0005] To address the aforementioned problems, one aspect of the present invention provides a modular mold for molding composite bus bodies, applicable to the molding of bus bodies of different models sharing a common gantry frame. The mold includes a general mold and multiple sets of feature molds. The outer surface of the general mold is a simple drawn surface of the inner surface of the bus gantry frame. Each set of feature molds is suitable for molding a feature structure of a bus body of one model, and each set of feature molds includes multiple feature molds. The feature molds are located on the general mold at positions corresponding to the feature structures of the bus body, and are detachably connected to the general mold. After the feature molds are connected to the general mold, the outer surface of the feature molds is used to mold the inner surface of the feature structure of the bus body.

[0006] Preferably, a set of the universal mold includes:

[0007] A general-purpose mold for the left side panel, wherein the outer surface of the general-purpose mold for the left side panel is a simple drawn surface of the inner surface of the left side panel of the bus gantry frame;

[0008] A universal mold for the right side panel, wherein the outer surface of the universal mold for the right side panel is a simple drawn surface of the inner surface of the right side panel of the bus gantry frame;

[0009] A universal mold for the top cover, wherein the outer surface of the universal mold for the top cover is a simple drawn surface of the inner surface of the top cover of the bus gantry frame;

[0010] A set of the aforementioned feature molds includes:

[0011] A left side panel feature mold is detachably connected to a left side panel universal mold. The left side panel feature mold is located on the left side panel universal mold at a position corresponding to the left side panel feature structure of the bus body. After the left side panel feature mold is connected to the left side panel universal mold, the outer surface of the left side panel feature mold is used to form the inner surface of the left side panel feature structure of the bus body.

[0012] A right side panel feature mold, which is detachably connected to a right side panel universal mold; the right side panel feature mold is located on the right side panel universal mold at a position corresponding to the right side panel feature structure of the bus body, and after the right side panel feature mold is connected to the right side panel universal mold, the outer surface of the right side panel feature mold is used to form the inner surface of the right side panel feature structure of the bus body;

[0013] A top cover feature mold; the top cover feature mold is detachably connected to the top cover general mold; the top cover feature mold is located on the top cover general mold at a position corresponding to the bus body top cover feature structure, and after the top cover feature mold is connected to the top cover general mold, the outer surface of the top cover feature mold is used to form the inner surface of the bus body top cover feature structure.

[0014] Preferably, the left side panel feature mold and the right side panel feature mold include a door mold and a window mold; the top cover feature mold includes an air outlet mold, an air return mold, a battery compartment mold, and a skylight mold.

[0015] Preferably, the universal mold includes a surface gel coat layer, a first structural fiberglass layer, an embedded metal plate layer, a second structural fiberglass layer, and a surface aluminum mesh layer stacked in sequence, with the surface gel coat layer located on the side of the universal mold closest to the outer surface.

[0016] Preferably, the raw material for preparing the surface gel coat layer is a mixture of epoxy resin system and aluminum powder, and the mass ratio of epoxy resin system to aluminum powder is 1:2-3; the thickness of the surface gel coat layer is 1-1.5 mm.

[0017] Preferably, the matrix material of the first structural fiberglass layer and / or the second structural fiberglass layer is an epoxy resin system, and the reinforcing material is glass fiber; the thickness of the first structural fiberglass layer and / or the second structural fiberglass layer is 10-15 mm, and the Tg is greater than 120°C.

[0018] Preferably, the embedded metal plate layer comprises a plurality of aluminum alloy plates arranged in sequence, with a spacing of 1-2 mm between adjacent aluminum alloy plates, and the gaps between adjacent aluminum alloy plates are filled with glass fiber yarn; the aluminum alloy plates are provided with a plurality of adhesive guiding structures, and the plurality of adhesive guiding structures are connected by interlacing glass fiber yarn.

[0019] Preferably, the feature mold includes a connecting base plate and a forming part, the forming part is disposed on the connecting base plate, the connecting base plate is used to connect with the general mold, and the forming part is used to form the feature structure of the bus body; the end of the part of the forming part used to form the opening structure is provided with a flange; the bottom edge of the connecting base plate is provided with a transition rounded corner.

[0020] Preferably, the feature mold and the general mold are connected by a fastening structure; the fastening structure includes a mounting hole, a through hole, an internal and external threaded bolt sleeve, and a bolt. The mounting hole is provided on the general mold and extends from the outer surface of the general mold into the embedded metal plate layer. The through hole is provided on the connecting base plate at a position corresponding to the mounting hole. The internal and external threaded bolt is sleeved in the mounting hole, and the bolt passes through the through hole and is connected to the internal and external threaded bolt sleeve by threads.

[0021] A second aspect of the present invention provides a method for molding a composite material bus body, which is completed using the above-mentioned modular mold for molding a composite material bus body, and includes the following steps:

[0022] S1. Take a general mold and select a set of feature molds according to the model of the composite bus body to be formed;

[0023] S2. Take out each feature mold from the selected set of feature molds, and set the corresponding feature mold on the general mold according to the position of different feature structures of the composite bus body to be formed;

[0024] S3. Connect the feature mold to the general mold;

[0025] S4. The reinforcing material is laid on the outer surface of the general mold and the feature mold, and then resin is injected and cured to obtain the composite material bus body.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] The modular mold and molding method for composite bus bodies of the present invention utilizes a set of general molds and multiple sets of feature molds. By switching and matching them as needed, it can efficiently and quickly produce composite bus bodies of different models that share a common gantry frame. It can not only realize changes in bus length, width, and height, but also changes in the number of steps, wheelbase, and the size and position of doors and windows. Moreover, there are no additional costs for style changes, which can effectively improve market competitiveness while reducing costs and increasing efficiency. By using a set of general molds and multiple sets of feature molds for one-to-many directional matching, it can be used to manufacture composite bus shell products of various specifications, realizing the centralized and unified modularization, standardization, functionality, high efficiency and low cost of composite bus molds. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the general mold in the modular mold for molding composite bus bodies according to an embodiment of the present invention;

[0029] Figure 2This is a schematic diagram of the structure of the characteristic molds of the left and right side panels in the modular mold for forming composite bus bodies according to an embodiment of the present invention;

[0030] Figure 3 This is a schematic diagram of the structure of the feature mold of the top cover in the modular mold for forming composite bus body according to an embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the structure of the left and right side feature molds and the general mold in the modular mold for forming composite bus body according to an embodiment of the present invention;

[0032] Figure 5 This is a schematic diagram of the structure of the modular mold for forming composite bus body according to an embodiment of the present invention after the top cover feature mold is connected to the general mold;

[0033] Figure 6 This is a schematic diagram of the structure of a bus body formed by a modular mold for forming composite material bus bodies according to an embodiment of the present invention.

[0034] Wherein: 1-General mold; 11-Surface gel coat layer; 12-First structural fiberglass layer; 13-Inlaid metal plate layer; 14-Second structural fiberglass layer; 15-Surface aluminum mesh layer; 2-Feature mold; 21-Connecting base plate; 22-Forming part; 23-Flanged edge; 24-Transition rounded corner; 25-Identification line; 3-Bus gantry frame; 4-Mounting hole; 5-Through hole; 6-Internal and external threaded bolt sleeve; 7-Bolt; 8-Left side panel; 9-Right side panel; 10-Top cover; 16-Silicone. Detailed Implementation

[0035] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0036] Example 1

[0037] Currently, molds used for fabricating composite bus bodies are typically monolithic, limiting their application to a single size and specification. However, a vehicle family sharing the same gantry frame usually comprises several different models, each with varying numbers of steps, wheelbases, and the size and position of doors and windows. Fixed molds, designed for only one model, cannot accommodate the changing requirements of an entire vehicle family. Therefore, this invention provides a modular mold for forming composite bus bodies. A single, universal mold can be used for an entire vehicle family, achieving multi-purpose functionality.

[0038] The modular mold for forming composite bus bodies in this embodiment is applicable to the forming of bus bodies of different models sharing a common gantry frame. It includes a set of general mold 1 and multiple sets of feature molds 2. The outer surface of the general mold 1 is a simple drawn surface of the inner surface of the bus gantry frame 3. Each set of feature molds is suitable for forming the feature structure of a bus body of one model. Each set of feature molds includes multiple feature molds. The feature mold 2 is located on the general mold 1 at the position corresponding to the feature structure of the bus body, and the feature mold 2 is detachably connected to the general mold 1. After the feature mold 2 is connected to the general mold 1, the outer surface of the feature mold 2 is used to form the inner surface of the feature structure of the bus body.

[0039] The modular mold for forming composite bus bodies in this embodiment is applicable to a family of models sharing the same gantry frame. In use, a universal mold can be designed according to the structure and dimensions of the composite bus body to be formed. Its outer surface is a simple drawn surface of the inner surface of the bus gantry frame. Within a family of models, the length, width, height, wheelbase, and other dimensions affecting the body outline may differ between models. The size and position of specific structures such as doors, windows, air inlets, and air outlets may also differ. Feature structures such as doors, windows, air inlets, and air outlets are formed using feature molds. A set of feature molds suitable for the specific model is selected. One set of feature molds includes multiple feature molds corresponding to different feature structures on the vehicle body. Based on the differences in these feature structures and their placement, appropriate feature molds are selected and placed at the designated positions on the universal mold. After connecting multiple feature molds with the universal mold, an overall mold for forming the composite bus body is formed. The length, width, height, and wheelbase of different vehicle models are reflected in the universal mold. The outer surface of the universal mold is a simple drawn surface of the inner surface of the bus gantry frame. For different vehicle models, the outline can be determined according to the actual length, width, height, wheelbase, etc. of the vehicle model. Lines are engraved on the universal mold. During molding, reinforcing material is laid inside the engraved lines of the universal mold. The final product is a product that conforms to the structure and size of the vehicle model.

[0040] The modular mold for forming composite bus bodies in this embodiment utilizes a set of general-purpose molds and multiple sets of feature molds. By switching and matching them as needed, it can efficiently and quickly produce composite bus bodies for different models that share a common gantry frame. It can not only realize changes in bus length, width, and height, but also changes in the number of steps, wheelbase, and the size and position of doors and windows. Moreover, there are no additional costs for style changes, which can effectively improve market competitiveness while reducing costs and increasing efficiency. By using a set of general-purpose molds and multiple sets of feature molds for one-to-many directional matching, it can be used to produce composite bus shell products of various specifications, realizing the centralized and unified modularization, standardization, functionality, high efficiency, and low cost of composite bus molds.

[0041] In some embodiments, the universal mold 1 can be a mold for forming an integral gantry frame, that is, the outer surface of the universal mold is a simple drawn surface of the inner surface of the bus gantry frame. The universal mold can also be divided into molds for different side panels. Preferably, a set of universal molds includes: a left side panel universal mold, a right side panel universal mold, and a top cover universal mold; the outer surface of the left side panel universal mold is a simple drawn surface of the inner surface of the left side panel of the bus gantry frame; the outer surface of the right side panel universal mold is a simple drawn surface of the inner surface of the right side panel of the bus gantry frame; and the outer surface of the top cover universal mold is a simple drawn surface of the inner surface of the top cover of the bus gantry frame. That is, the left side panel universal mold, the right side panel universal mold, and the top cover universal mold are respectively simple drawn surfaces of the inner surface of the gantry frame decomposed on the left piece, the right piece, and the top piece. The left side panel universal mold, the right side panel universal mold, and the top cover universal mold respectively form the left side panel, the right side panel, and the top cover of the bus body, and then the left side panel, the right side panel, and the top cover are connected to form the bus body.

[0042] Furthermore, the length, height, and width of the left side panel universal mold, the right side panel universal mold, and the roof universal mold are adjusted according to the actual body structure of the models that share the same gantry frame. Specifically, the length, height, and width of the left side panel universal mold, the right side panel universal mold, and the roof universal mold should be the maximum value of the length, height, and width of all models in the model family that share the same gantry frame. Any model in the model family whose length, height, and width do not exceed the universal mold can be formed using the universal mold.

[0043] In some embodiments, a set of feature molds includes: a left side feature mold, a right side feature mold, and a top cover feature mold. The left side feature mold is detachably connected to a left side universal mold. The left side feature mold is located on the left side universal mold at a position corresponding to the left side feature structure of the bus body, and after the left side feature mold is connected to the left side universal mold, the outer surface of the left side feature mold is used to form the inner surface of the left side feature structure of the bus body. The right side feature mold is detachably connected to a right side universal mold. The right side feature mold is located on the right side universal mold at a position corresponding to the right side feature structure of the bus body, and after the right side feature mold is connected to the right side universal mold, the outer surface of the right side feature mold is used to form the inner surface of the right side feature structure of the bus body. The top cover feature mold is detachably connected to a top cover universal mold. The top cover feature mold is located on the top cover universal mold at a position corresponding to the top cover feature structure of the bus body, and after the top cover feature mold is connected to the top cover universal mold, the outer surface of the top cover feature mold is used to form the inner surface of the top cover feature structure of the bus body.

[0044] In some embodiments, to further improve the structural strength, molding effect, and connection strength with the feature mold of the general mold, preferably, the general mold 1 includes a surface gel coat layer 11, a first structural fiberglass layer 12, an embedded metal plate layer 13, a second structural fiberglass layer 14, and a surface aluminum mesh layer 15 stacked in sequence, with the surface gel coat layer 11 located on the side of the general mold closer to the outer surface.

[0045] The function of the surface gel coat layer is to densely adhere to the fiberglass layer of the first structure of the mold after casting, thereby improving the wear resistance of the mold surface. In some embodiments, the raw materials for preparing the surface gel coat layer 11 are a mixture of epoxy resin system and aluminum powder, with the mass ratio of epoxy resin system to aluminum powder being 1:2-3; further, the mass ratio of epoxy resin system to aluminum powder is 1:2.5. The thickness of the surface gel coat layer is 1-1.5 mm.

[0046] The function of the first structural fiberglass layer 12 and the second structural fiberglass layer 14 is to ensure the strength and high-temperature resistance of the general-purpose mold. Preferably, the matrix material of the first structural fiberglass layer and / or the second structural fiberglass layer is an epoxy resin system, and the reinforcing material is glass fiber; the thickness of the first structural fiberglass layer and / or the second structural fiberglass layer is 10-15mm, and the Tg is greater than 120℃. This satisfies the curing temperature requirements of the mold and the product.

[0047] The function of the embedded metal plate layer 13 is to connect to the feature mold via bolts, thereby increasing the effective pull-out force. In some embodiments, the embedded metal plate layer can be made of iron plate, aluminum plate, steel plate, etc., and preferably, the embedded metal plate layer is an aluminum alloy plate.

[0048] In some embodiments, the embedded aluminum alloy plate can be a single, integral aluminum alloy plate or composed of multiple aluminum alloy plates arranged in sequence. Preferably, the embedded metal plate layer 13 includes multiple aluminum alloy plates arranged sequentially, with adjacent aluminum alloy plates spaced 1-2 mm apart, and the gaps between adjacent aluminum alloy plates filled with glass fiber yarn; the aluminum alloy plates are provided with multiple adhesive guiding structures, which are connected by interlacing glass fiber yarn. With this arrangement, when the first and second structural fiberglass layers are formed on the aluminum alloy plates, the adhesive guiding structures facilitate the transfer of resin in the reinforcing materials laid on the aluminum alloy plates, ensuring uniform and consistent resin distribution in the formed first and second structural fiberglass layers, resulting in higher strength; the multiple aluminum alloy plates are spaced apart, the gaps are filled with glass fiber yarn, and the glass fiber yarn is interlaced between the adhesive guiding structures, which increases the connection between the aluminum alloy plates and the first and second structural fiberglass layers, avoids delamination during cyclic heating and cooling, and prevents resin enrichment in the adhesive guiding structures.

[0049] Furthermore, the specific dimensions of the aluminum alloy sheet are not limited. Preferably, the aluminum alloy sheet adopts any of the dimensions of 2000×1000×10mm or 2000×1100×10mm.

[0050] Furthermore, the adhesive guiding structure is arranged in an array on the aluminum alloy plate. Preferably, the adhesive guiding structure includes multiple adhesive guiding holes and adhesive guiding grooves disposed between adjacent adhesive guiding holes. The specific dimensions of the adhesive guiding holes and adhesive guiding grooves are not particularly limited. Preferably, the diameter of the adhesive guiding holes is [missing information]. The center-to-center spacing between adjacent adhesive guiding holes is 10cm; the width of the adhesive guiding groove is 1.5±0.3mm, and the depth of the adhesive guiding groove is 1.5±0.3mm.

[0051] The function of the surface aluminum mesh layer 15 is to improve the uniformity of heat conduction on the lower end face of the mold. Preferably, the surface aluminum mesh layer is a diamond-shaped aluminum mesh.

[0052] In some embodiments, the general mold 1 is also provided with marking lines or marking points. The marking lines or marking points are set according to the needs of the product manufacturing molding process and assembly process, and the marking lines or marking points are accurately positioned, clear and smooth. The relative position of the general mold and the feature mold can be determined according to the positioning marking lines on the outer surface of the general mold, and its assembly accuracy is ±0.5mm.

[0053] In some embodiments, the feature structures on the composite material bus body include doors, windows, air vents, air return vents, battery compartments, sunroofs, etc. Therefore, preferably, the left side panel feature mold and the right side panel feature mold include door molds and window molds; the roof feature mold includes air vent molds, air return vent molds, battery compartment molds, and sunroof molds. The feature molds are not limited to the above-mentioned molds and can be adjusted according to the structure of the actual manufactured bus body.

[0054] In some embodiments, the feature mold is made of fiberglass composite material with a Tg value > 120°C, which meets the curing temperature requirements of the mold and the product. The outer surface of the feature mold is covered with a surface gel coat layer.

[0055] Preferably, the feature mold 2 includes a connecting base plate 21 and a forming part 22. The forming part 22 is disposed on the connecting base plate 21, which is used to connect with the general mold 1. The forming part 22 is used to form the feature structure of the bus body. The end of the forming part used to form the opening structure is provided with a flange 23. The bottom edge of the connecting base plate is provided with a transition rounded corner 24. When the feature mold is used for the surface feature extraction process, it is necessary to ensure that the extracted forming surface conforms to the process characteristics of composite material laying and conforms to the external dimensions of the feature structure. Further, the feature mold 2 is in the shape of a hollow boss.

[0056] Among them, the flange 23 is designed to meet the requirements of the product forming process, and the flange of the mold is ≥50mm. Furthermore, the vertical edge of the flange 23 is cut and polished smoothly, without sharp corners or sharp edges.

[0057] Specifically, at the 24th transition rounded corner, putty should be used to level it with the lower horizontal surface, and Teflon stickers should be wrapped around the perimeter of the transition rounded corner. This prevents damage to the putty during product demolding, avoiding repeated repairs, and also prevents glue from entering the joint interface.

[0058] Among them, the connecting base plate 21 is the main load-bearing plate for connecting the feature mold and the general mold. Preferably, the design thickness of the connecting base plate 21 is 10-15mm.

[0059] Preferably, the feature mold 2 is also provided with a marking line 25. The marking line 25 is the boundary marking position when the product is reproduced, and the wall thickness here is designed to be 6-10mm.

[0060] In some embodiments, the feature mold 2 and the general mold 1 are connected by a fastening structure. The fastening structure can be implemented using various existing fasteners. Preferably, the fastening structure includes a mounting hole 4, a through hole 5, internal and external threaded bolt sleeves 6, and a bolt 7. The mounting hole 4 is located on the general mold 1 and extends from the outer surface of the general mold 1 into the embedded metal plate layer 13. The through hole 5 is located on the connecting base plate 21 at a position corresponding to the mounting hole 4. The internal and external threaded bolt sleeves 6 are located in the mounting hole 4. The bolt 7 passes through the through hole 5 and is threadedly connected to the internal and external threaded bolt sleeves 6. The bolt 7 penetrates deep into the internal and external threaded bolt sleeves 6 and is fastened, ensuring good fit with the general mold and providing sufficient connection strength. It will not fall off or shift during repeated demolding in production.

[0061] Preferably, the height of the internal and external threaded bolt sleeve 6 is 15-20mm, and the specification is M12-M16.

[0062] Preferably, the bolt 7 is height-matched with the feature mold 2, with a height range of 25mm-40mm.

[0063] Preferably, a flat washer is provided below the nut of bolt 7, which can increase the force-bearing area with the fiberglass surface of the feature mold.

[0064] Preferably, the gap between the top cover feature mold and the bolt 7 is filled with silicone 16. This ensures a smooth surface and facilitates easy removal of the bolt.

[0065] Example 2

[0066] The molding method for the composite material bus body of the present invention is completed using the modular mold for molding the composite material bus body of Example 1, and includes the following steps:

[0067] S1. Take a general mold and select a set of feature molds according to the model of the composite bus body to be formed;

[0068] S2. Take out each feature mold from the selected set of feature molds, and set the corresponding feature molds on the general mold according to the position of different feature structures of the composite material bus body to be formed; including the left side feature mold, the right side feature mold, and the roof feature mold; the left and right side feature molds are mainly door frames and window frames, and the roof feature molds are mainly battery compartments and sunroofs, etc.

[0069] S3. Connect the feature mold and the general mold through a fastening structure to obtain the left side integral mold, the right side integral mold, and the top cover integral mold;

[0070] S4. The reinforcing fibers are laid on the outer surfaces of the left side panel mold, the right side panel mold, and the top cover mold. Then, resin is injected and cured to form the left side panel 8, right side panel 9, and top cover 10 of the bus body. The left side panel 8, right side panel 9, and top cover 10 of the bus body are connected to obtain the composite material bus body.

[0071] The molding method for composite bus bodies in this embodiment adopts a modular design approach of general molds + feature molds. By adjusting multiple sets of feature molds, the production of composite bus bodies for different models sharing a common gantry frame can be achieved. There are no additional costs for changing the model style. At the same time, it saves the cycle and cost of multiple design and mold openings. While reducing costs and increasing efficiency, it can quickly respond to market demands and complete production, effectively improving market competitiveness.

[0072] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A modular mold for forming a composite material bus body, characterized by, The modular die is suitable for forming a plurality of bus bodies of different models sharing a common portal frame, and comprises: a common die and a plurality of feature dies; the common die has a simple drawing surface corresponding to the inner surface of the bus portal frame; each of the feature dies is suitable for forming a feature structure of a bus body of a model, and each of the feature dies comprises a plurality of feature dies; the feature dies are arranged at positions corresponding to the feature structure of the bus body on the common die, and the feature dies are detachably connected to the common die; after the feature dies are connected to the common die, the outer surface of the feature dies is used to form the inner surface of the feature structure of the bus body; the common die comprises: a left side wall common die, which has a simple drawing surface corresponding to the inner surface of the left side wall of the bus portal frame; a right side wall common die, which has a simple drawing surface corresponding to the inner surface of the right side wall of the bus portal frame; a roof common die, which has a simple drawing surface corresponding to the inner surface of the roof of the bus portal frame; the feature dies comprise: a left side wall feature die, which is detachably connected to the left side wall common die; the left side wall feature die is arranged at a position corresponding to the feature structure of the left side wall of the bus body on the left side wall common die, and after the left side wall feature die is connected to the left side wall common die, the outer surface of the left side wall feature die is used to form the inner surface of the feature structure of the left side wall of the bus body; a right side wall feature die, which is detachably connected to the right side wall common die; the right side wall feature die is arranged at a position corresponding to the feature structure of the right side wall of the bus body on the right side wall common die, and after the right side wall feature die is connected to the right side wall common die, the outer surface of the right side wall feature die is used to form the inner surface of the feature structure of the right side wall of the bus body; a roof feature die, which is detachably connected to the roof common die; the roof feature die is arranged at a position corresponding to the feature structure of the roof of the bus body on the roof common die, and after the roof feature die is connected to the roof common die, the outer surface of the roof feature die is used to form the inner surface of the feature structure of the roof of the bus body; the common die comprises a surface gelcoat layer, a first structural glass steel layer, an embedded metal plate layer, a second structural glass steel layer and a surface aluminum mesh layer arranged in sequence; the surface gelcoat layer is arranged on the side of the common die close to the outer surface.

2. The modular die for forming a composite bus body according to claim 1, wherein: the left side wall feature die and the right side wall feature die comprise a door die and a window die; and the roof feature die comprises an air outlet die, an air return inlet die, a battery slot die and a skylight die.

3. The modular die for forming a composite bus body according to claim 1, wherein: The preparation raw material of the surface gel coat layer is a mixture of an epoxy resin system and aluminum powder, and the mass ratio of the epoxy resin system to the aluminum powder is 1:2-3; the thickness of the surface gel coat layer is 1-1.5 mm.

4. The modular mold for forming a composite material bus body according to claim 1, characterized in that: The base material of the first structural glass steel layer and / or the second structural glass steel layer is an epoxy resin system, and the reinforcing material is glass fiber; the thickness of the first structural glass steel layer and / or the second structural glass steel layer is 10-15 mm, and Tg>120℃.

5. The modular mold for forming a composite material bus body according to claim 1, characterized in that: The inner-embedded metal plate layer comprises a plurality of aluminum alloy plates arranged in sequence, the adjacent aluminum alloy plates are spaced apart by 1-2 mm, and the gap between the adjacent aluminum alloy plates is filled with glass fiber yarn; a plurality of glue guiding structures are arranged on the aluminum alloy plate, and the plurality of glue guiding structures are connected by glass fiber yarn.

6. The modular mold for forming a composite material bus body according to claim 1, characterized in that: The feature mold comprises a connecting bottom plate and a forming part, the forming part is arranged on the connecting bottom plate, the connecting bottom plate is used for connecting with the general mold, and the forming part is used for forming a feature structure of a bus body; the end of the part for forming an opening structure on the forming part is provided with a flange; and the bottom edge of the connecting bottom plate is provided with a transition fillet.

7. The modular mold for forming a composite material bus body according to claim 6, characterized in that: The feature mold is connected with the general mold through a fastening structure; the fastening structure comprises a mounting hole, a through hole, an internal and external thread bolt sleeve and a bolt, the mounting hole is arranged on the general mold and extends from the outer surface of the general mold into the inner-embedded metal plate layer, the through hole is arranged on the connecting bottom plate at a position corresponding to the mounting hole, the internal and external thread bolt sleeve is arranged in the mounting hole, and the bolt is threadedly connected with the internal and external thread bolt sleeve through the through hole.

8. A method of forming a composite material bus body, characterized by, The modular mold for forming a composite material bus body is completed by using the modular mold for forming a composite material bus body according to any one of claims 1-7, comprising the following steps: S1. Taking a general mold, and selecting a corresponding set of feature molds according to the type of the composite material bus body to be formed; S2. Taking each feature mold from the selected set of feature molds, and arranging the corresponding feature mold on the general mold according to the position of the different feature structures of the composite material bus body to be formed; S3. Connecting the feature mold with the general mold; S4. Laying the reinforcing material on the outer surface of the general mold and the feature mold, then pouring resin, and curing and forming to obtain the composite material bus body.

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