High-strength lightweight detachable splicing composite automobile roof and processing technology thereof

Abstract

The application discloses a high-strength lightweight composite material detachable splicing automobile roof and a processing technology thereof, and relates to the technical field of automobile roofs. Technical scheme points of the application are as follows: the automobile roof comprises a plurality of detachable roof sub-plates, the roof sub-plate comprises an inner plate and an outer plate, the inner plate comprises a honeycomb paper core layer, the honeycomb paper core layer is wrapped and connected with special glass fiber cloth on the peripheral side, the two side surfaces of the honeycomb paper core layer are provided with reinforced glass fiber layers, the reinforced glass fiber layers comprise continuous glass fibers, the surface of the continuous glass fibers is provided with glass fiber surface felt, and the outer surfaces of the special glass fiber cloth and the glass fiber surface felt are both provided with polyurethane layers. The application aims to provide a high-strength lightweight composite material detachable splicing automobile roof and a processing technology thereof.

Description

Technical Field

[0001] This invention relates to the field of automotive roof technology, and more specifically, to a high-strength, lightweight composite material detachable and splicable automotive roof and its processing technology. Background Technology

[0002] As the automotive interior industry increasingly trends towards high performance, environmental friendliness, low carbon emissions, and low VOCs, the requirements for car headliners are also becoming more stringent. In addition to enhancing the aesthetics of the car interior, car headliners also serve to insulate, absorb sound, and provide heat insulation.

[0003] With the development of the automotive industry, some car roofs are now connected to the vehicle body in a detachable and modular manner, allowing the car to switch freely between convertible and non-convertible modes. This makes it easy to remove and install the roof, as well as to store and transport it. Detachable hardtops provide very convenient options for off-road and convertible scenarios, meeting personalized and practical usage needs.

[0004] The above-mentioned technical solution is based on the fact that the car roof is assembled from several roof panels. After long-term installation, disassembly and use, the edges of the panels are prone to wear and cracking, which leads to a decrease in the waterproof performance of the edges and thus affects its normal use function.

[0005] Therefore, a new technical solution is urgently needed to address the technical issues in the aforementioned vehicle usage requirements. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the present invention aims to provide a high-strength, lightweight composite material detachable and splicable automotive roof and its processing technology.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution: a high-strength, lightweight composite material detachable and splicable car roof, the car roof comprising several detachably connected roof panels, each roof panel comprising an inner panel and an outer panel, the inner panel comprising a honeycomb paper core layer, the periphery of the honeycomb paper core layer being covered and connected with a special glass fiber cloth, the two side surfaces of the honeycomb paper core layer being provided with reinforcing glass fiber layers, the reinforcing glass fiber layers comprising continuous glass fibers, the surface of the continuous glass fibers being provided with a glass fiber surface mat, and both the outer surfaces of the glass fiber surface mat and the special glass fiber cloth being provided with a polyurethane layer.

[0008] By adopting the above technical solution and setting a reinforced fiberglass layer, the structural strength of each panel is effectively improved, thereby increasing the strength of the final car roof after installation. Furthermore, by wrapping the periphery of the honeycomb paper core layer with special fiberglass cloth, the structural strength at the edges of each panel is improved. After long-term use, the car roof can effectively prevent cracking at the edges of the panels, thereby reducing water leakage and effectively extending its service life.

[0009] The present invention is further configured such that: a plurality of metal embedded parts are provided in the polyurethane layer on the inner surface of the inner plate, and a glass fiber sheet is provided between the embedded parts and the polyurethane layer.

[0010] A processing technology for a high-strength, lightweight composite material detachable and splicable automotive roof includes the following steps:

[0011] S1. Inner plate preparation:

[0012] S1.1, Paper core preparation: The honeycomb paper core is stretched, heated and shaped, and cut into honeycomb paper core boards of specified size. The surface is engraved and the edges are cut to obtain the honeycomb paper core layer.

[0013] S1.2 Paper core edge wrapping: Apply glue to the edges of the sides and two sides of the honeycomb paper core layer, and cut special glass fiber cloth into strips of a certain length to wrap and paste it around the periphery of the honeycomb paper core layer.

[0014] S1.3 Preparation of the reinforced fiberglass layer: After cutting the continuous glass fibers and glass fiber surface mat into the specified size, stack them neatly to form a reinforced fiberglass layer;

[0015] S1.4 Polyurethane spraying: Take the reinforcing glass fiber layer from S1.3 and spray the low-foaming polyurethane evenly onto the surface of the glass fiber mat using a spray gun.

[0016] S1.5 Molding preparation: Place a layer of reinforced fiberglass in the thermoforming mold, with the polyurethane-coated surface facing down, and place the honeycomb paper core layer with the edge wrapped in S1.2 on the surface of the reinforced fiberglass layer. Finally, place another layer of reinforced fiberglass on the surface of the honeycomb paper core layer, with the polyurethane-coated surface facing up.

[0017] S1.6 Hot pressing: The hot pressing is performed by the hot forming mold, and the inner plate is formed after cooling.

[0018] S2. Outer panel preparation:

[0019] S2.1, Sheet preparation: Take SMC fiberglass sheets and cut them into sheets of the specified size and shape;

[0020] S2.2 Hot pressing: The sheet material from S2.1 is placed into a hot pressing mold and hot pressed. After cooling, the outer panel is formed.

[0021] S2.3, Spray painting: Apply tape to the adhesive strip between the inner surface of the outer panel and the inner panel, and spray conductive paint onto its surface.

[0022] S2.4 Powder coating: Powder coating is performed on the outer surface of the outer panel using a powder coating robot, and the paint surface is formed by high-temperature baking.

[0023] S3. Finished Product Assembly:

[0024] S3.1 Inner panel and outer panel assembly: The inner panel and outer panel are glued and fixed together;

[0025] S3.2 Installation of other accessories: Adhere the interior felt to the inner surface of the inner panel with glue, and install the connectors through the screw holes of the metal embedded parts.

[0026] The present invention is further configured such that: in step S1.5, before placing the first layer of reinforcing glass fiber, a metal pre-embedded part is placed at a designated position in the hot pressing mold, and a glass fiber sheet is placed on the lower surface of the metal pre-embedded part.

[0027] The present invention is further configured such that: in steps S1.6 and S2.2, after the inner plate and the outer plate are hot-pressed and cooled to form, they are ground to remove burrs, and holes are drilled and tapped at the screw holes of the metal embedded parts of the inner plate.

[0028] The present invention is further configured such that: in step S1.6, after the inner panel is hot-pressed and cooled to form, the adhesive path on the outer surface of the inner panel is polished by a laser polishing device, and after polishing, it is wiped with alcohol and cleaned by blowing off dust to improve its bonding strength with the outer panel.

[0029] The present invention is further configured such that: after step 2.4, the adhesive path of the bonding path on the inner surface of the outer panel is polished by a laser polishing device.

[0030] The present invention is further configured such that: after laser polishing, the adhesive path of the outer panel is polished by a polishing machine, and finally wiped with alcohol and blown away dust.

[0031] The present invention has the following beneficial effects: by setting a reinforcing fiberglass layer, the structural strength of each panel is effectively improved, thereby improving the strength of the final car roof after installation. Furthermore, by wrapping the periphery of the honeycomb paper core layer with special fiberglass cloth, the structural strength at the edge of each panel is improved. Moreover, after long-term use, the car roof can effectively prevent cracking at the edge of the panels, thereby reducing water leakage and effectively extending its service life. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the ceiling panel structure in specific embodiment 1;

[0033] Figure 2 This is a partial cross-sectional structural diagram of the inner plate in specific embodiment 1;

[0034] Figure 3 for Figure 2 A magnified view of part A in the middle;

[0035] Figure 4 This is a side view of the reinforced fiberglass layer in specific embodiment 1.

[0036] Figure descriptions: 1. Ceiling panel; 2. Inner panel; 3. Outer panel; 4. Interior felt; 5. Honeycomb paper core layer; 6. Special fiberglass cloth; 7. Reinforced fiberglass layer; 701. Continuous fiberglass; 702. Fiberglass surface felt; 8. Polyurethane layer; 9. Metal embedded parts; 10. Fiberglass sheet. Detailed Implementation

[0037] The present invention will be further described in detail below with reference to the accompanying drawings.

[0038] Identical parts are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions toward or away from the geometric center of a specific part, respectively. Specific Implementation Example 1:

[0040] As shown in the figure, a high-strength, lightweight composite material detachable and splicable car roof is provided. The car roof includes several detachable and connectable roof panels 1. Each roof panel includes an inner panel 2 and an outer panel 3. The inner surface of the inner panel 2 is covered with interior felt 4 and several connectors (not shown in the figure) for connecting the panels and installing the car roof onto the car.

[0041] The inner panel 2 includes a honeycomb paper core layer 5, and a special glass fiber cloth 6 is wrapped and connected around the periphery of the honeycomb paper core layer 5. Reinforcing glass fiber layers 7 are provided on both sides of the honeycomb paper core layer 5. The reinforcing glass fiber layers 7 include continuous glass fibers 701. A glass fiber surface mat 702 is provided on the surface of the continuous glass fibers 701. The glass fiber surface mat 702 and the outer surface of the special glass fiber cloth 6 are coated with low-foaming polyurethane and then a polyurethane layer 8 is formed after hot pressing and cooling.

[0042] By setting a reinforced fiberglass layer 7, the structural strength of each panel is effectively improved, thereby increasing the strength of the final car roof after installation. Furthermore, by wrapping the periphery of the honeycomb paper core layer 5 with special fiberglass cloth 6, the structural strength at the edges of each panel is enhanced. After prolonged use, this car roof can effectively prevent cracking at the edges of the panels, reducing water leakage and thus effectively extending its service life.

[0043] Several metal embedded parts 9 are provided in the polyurethane layer on the inner surface of the inner panel 2. A glass fiber sheet 10 is provided between the metal embedded parts and the polyurethane layer. The metal embedded parts facilitate the installation of various assembly parts in the future, and the glass limiting sheet effectively improves the stability and strength of the embedded parts after installation, thereby ensuring the stability and strength of the connection between two adjacent panels. Specific Implementation Example 2:

[0045] A manufacturing process for an automotive roof includes the following steps:

[0046] S1. Inner plate preparation:

[0047] S1.1, Paper core preparation: The honeycomb paper core is stretched, heated and shaped, and cut into honeycomb paper core boards of a specified size. The surface is engraved and the edges are cut to obtain a honeycomb paper core layer 5 of the size and shape corresponding to the board to be processed.

[0048] S1.2 Paper core edge wrapping: Spray glue on the side edges and the edges of both sides of the honeycomb paper core layer 5, and cut the special glass fiber cloth 6 into strips of a certain length, wrap and paste it around the periphery of the honeycomb paper core layer 5, and use glue to ensure the stability of the special glass fiber wrapping around the periphery of the honeycomb paper core layer 5.

[0049] S1.3 Preparation of reinforced fiberglass layer: After cutting the continuous glass fiber 701 and the glass fiber surface mat 702 to the specified size, they are stacked neatly to form the reinforced fiberglass layer 7. The two sides of the glass fiber surface mat 702 are longer than the continuous glass fiber 701. The two sides of the glass fiber surface mat 702 are folded upward and attached to the two sides of the surface of the continuous glass fiber 701 to effectively prevent the edge cracking during the later separation of the board.

[0050] S1.4 Polyurethane spraying: Take the reinforcing glass fiber layer 7 from S1.3 and spray the low-foaming polyurethane evenly onto the surface of its glass fiber surface mat 702 through a spray gun.

[0051] S1.5 Molding preparation: Place the metal embedded part at the designated position in the thermoforming mold, and place the glass fiber sheet on the lower surface of the metal embedded part. Place a layer of reinforcing glass fiber 7 above the metal embedded part in the thermoforming mold, with the polyurethane sprayed surface facing down. Place the honeycomb paper core layer 5 with the edge wrapped in S1.2 on the surface of the reinforcing glass fiber layer 7. Finally, place another reinforcing glass fiber layer 7 on the surface of the honeycomb paper core layer 5, with the polyurethane sprayed surface facing up.

[0052] S1.6 Hot pressing: The hot forming mold is used for hot pressing. After hot pressing and cooling, the inner plate 2 is formed. The inner plate 2 is ground to remove the flash, and the screw holes of the metal embedded parts of the inner plate 2 are drilled and tapped.

[0053] S1.7 Inner Panel 2 Adhesive Path Treatment: The adhesive path on the outer surface of the inner panel 2 is polished by laser polishing equipment. After polishing, it is wiped with alcohol and blown clean to improve its bonding strength with the outer panel 3.

[0054] S2. Outer panel preparation:

[0055] S2.1, Sheet preparation: Take SMC fiberglass sheets and cut them into sheets of the specified size and shape;

[0056] S2.2 Hot pressing: The sheet material in S2.1 is placed into the hot forming mold for hot pressing. After hot pressing and cooling, the outer panel 3 is formed. The outer panel 3 is then polished to remove burrs.

[0057] S2.3, Painting: Apply tape to the adhesive strip between the inner surface of the outer panel 3 and the inner panel 2, and spray conductive paint onto its surface.

[0058] S2.4 Powder spraying: Powder spraying is performed on the outer surface of the outer panel 3 by a powder spraying robot, and the paint surface is formed by high temperature baking.

[0059] S2.5: Outer panel adhesive path treatment: The adhesive path on the inner surface of the outer panel 3 is polished by laser polishing equipment. After laser polishing, the adhesive path on the outer panel is polished by polishing machine. Finally, it is wiped with alcohol and blown away dust.

[0060] S3. Finished Product Assembly:

[0061] S3.1 Assembly of inner and outer panels:

[0062] S3.1.1 Installation preparation: Place the inner panel 2 and the outer panel 3 into their respective positioning fixtures, and wipe the adhesive lines of the inner panel 2 and the outer panel 3 with isopropyl alcohol.

[0063] S3.1.2 Glue application: Glue is applied to the adhesive path on the inner surface of the outer panel 3 by a robotic arm;

[0064] S3.1.3, Adhesion: Attach the inner surface of the outer panel 3 to the outer surface of the inner panel 2 with adhesive;

[0065] S3.2 Installation of other accessories: Adhere the interior felt 4 to the inner surface of the inner panel 2 with glue, install the connectors through the screw holes of the metal embedded parts, and finally install the sealing strip on the periphery of the panel.

[0066] The specific embodiments are merely illustrative of the present invention and are not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to these embodiments without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. A high-strength, lightweight composite material detachable and splicable automotive roof and its processing technology, characterized in that: The car roof includes several detachable roof panels (1), each roof panel (1) includes an inner panel (2) and an outer panel (3). The inner panel (2) includes a honeycomb paper core layer (5), and a special glass fiber cloth (6) is wrapped around the periphery of the honeycomb paper core layer (5). Reinforcing glass fiber layers (7) are provided on both sides of the honeycomb paper core layer (5). The reinforcing glass fiber layer (7) includes continuous glass fibers (701), and a glass fiber surface mat (702) is provided on the surface of the continuous glass fibers (701). Both the outer surfaces of the glass fiber surface mat (702) and the special glass fiber cloth (6) are provided with a polyurethane layer (8). The processing technology includes the following steps: S1. Inner plate preparation: S1.1, Paper core preparation: The honeycomb paper core is stretched, heated and shaped, and cut into honeycomb paper core boards of specified size. The surface is engraved and the edges are cut to obtain the honeycomb paper core layer (5). S1.2, Paper core edge wrapping: Spray glue on the side edge and the edges of both sides of the honeycomb paper core layer (5), and cut special glass fiber cloth (6) into strips of a certain length and wrap and paste them around the periphery of the honeycomb paper core layer (5). S1.3 Preparation of the reinforced fiberglass layer: After cutting the continuous glass fiber (701) and the glass fiber surface mat (702) into the specified size, they are stacked neatly to form the reinforced fiberglass layer (7); S1.4, Polyurethane spraying: Take the reinforcing glass fiber layer (7) from S13 and spray the low-foaming polyurethane evenly onto the surface of its glass fiber surface mat (702) through a spray gun. S1.5, Molding preparation: Place a layer of reinforced glass fiber (7) in the thermoforming mold, with the polyurethane sprayed surface facing down, and place the honeycomb paper core layer (5) with the edge wrapped in S1.2 on the surface of the reinforced glass fiber layer (7). Finally, place another reinforced glass fiber layer (7) on the surface of the honeycomb paper core layer (5), with the polyurethane sprayed surface facing up. S1.6, Hot pressing: The hot forming mold is used to perform hot pressing, and after the hot pressing is cooled, the inner plate (2) is formed as the finished product; S2. Outer panel preparation: S2.1, Sheet preparation: Take SMC fiberglass sheets and cut them into the specified size and shape; S2.2, Hot pressing: The sheet material in S2.1 is placed into the hot forming mold for hot pressing. After hot pressing and cooling, the outer panel (3) is formed as the finished product. S2.3, Spray painting: Apply tape to the adhesive strip between the inner surface of the outer panel (3) and the inner panel (2), and spray conductive paint on its surface; S2.4 Powder spraying: Powder spraying is performed on the outer surface of the outer panel (3) by a powder spraying robot, and the paint surface is formed by high temperature baking; S3. Finished Product Assembly: S3.1, Assembly of inner and outer panels: The inner panel (2) and the outer panel (3) are glued together and fixed. S3.2 Installation of other accessories: The interior felt is glued to the inner surface of the inner panel (2), and the connectors are installed through the screw holes of the metal embedded parts; A number of metal embedded parts (9) are provided in the polyurethane layer (8) on the inner surface of the inner plate (2), and a glass fiber sheet (10) is provided between the metal embedded parts (9) and the polyurethane layer (8). In step S1.5, before placing the first layer of reinforcing glass fiber (7), a metal embedded part is placed at a designated position in the hot pressing mold, and a glass fiber sheet (10) is placed on the lower surface of the metal embedded part. In steps S1.6 and S2.2, after the inner plate (2) and the outer plate (3) are hot-pressed and cooled to form, they are ground to remove the flash, and the screw holes of the metal embedded parts of the inner plate (2) are drilled and tapped.

2. The processing technology for an automobile roof according to claim 1, characterized in that: In step S1.6, after the inner plate (2) is hot-pressed and cooled to form, the adhesive path on the outer surface of the inner plate (2) is polished by a laser polishing device. After polishing, it is wiped with alcohol and blown clean to improve its bonding strength with the outer plate (3).

3. The processing technology for an automobile roof according to claim 1, characterized in that: After step 2.4, the adhesive path of the inner surface of the outer panel (3) is polished by laser polishing equipment.

4. The processing technology for an automobile roof according to claim 3, characterized in that: After laser polishing, the adhesive path of the outer panel is polished and polished using a polishing machine, and finally wiped with alcohol and blown away dust.

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