A green and environmentally friendly filling method for automotive energy-absorbing boxes using metal shavings.

Abstract

This invention belongs to the field of automotive parts technology and relates to a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings. This invention involves pressure-shaping pre-treated metal shavings and then filling them into the energy-absorbing box, significantly improving the mechanical properties of the box. Pre-treatment of the metal shavings facilitates recycling and reuse, while also removing contaminants to prevent corrosion of the box. Furthermore, pressure-shaping the pre-treated metal shavings according to the box size facilitates filling and ensures sufficient contact between the shaped shavings and the box, thus improving performance. Controlling the porosity of the shaped metal shavings based on the pressure further enhances the box's performance. This invention uses metal shavings to fill the energy-absorbing box, achieving metal recycling, avoiding resource waste, and eliminating environmental pollution during production.

Description

Technical Field

[0001] This invention belongs to the field of automotive parts technology and relates to a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings. Background Technology

[0002] Energy-absorbing boxes, as a crucial safety component in modern automotive design, play a key role in absorbing impact energy and protecting passengers from serious injury during a collision. Their superior energy-absorbing properties are directly related to the overall crashworthiness of a vehicle and are one of the important indicators for evaluating automotive safety performance.

[0003] Single-cell and multi-cell thin-walled structures are two common optimization methods. Single-cell thin-walled structures can achieve controllable plastic deformation during collisions, thus effectively absorbing collision energy. Multi-cell thin-walled structures go a step further, forming a more complex energy absorption network through multiple interconnected thin-walled units. This structure not only improves energy absorption efficiency but also enhances the overall stability and deformation resistance of the energy-absorbing box. However, multi-cell thin-walled structures require more material to construct, which increases manufacturing costs and the weight of the energy-absorbing box to some extent.

[0004] Induction structures, by incorporating specific guide grooves or ribs on the energy-absorbing box, guide the compression deformation path during a collision, allowing the energy-absorbing box to fold or collapse in a predetermined manner. This method not only improves energy absorption efficiency but also helps control the vehicle's attitude after a collision, reducing the risk of secondary collisions. However, the manufacturing process of induction structures may generate a certain amount of residual waste, resulting in resource waste.

[0005] Currently, the application of filling materials in energy-absorbing boxes is becoming increasingly widespread. Commonly used filling materials include aluminum foam, polyurethane foam, and honeycomb materials, which are lightweight, high-strength, and have excellent energy absorption properties. These filling materials can deform rapidly upon impact and absorb a large amount of energy, effectively reducing the impact on passengers. However, the manufacturing process of these materials often involves a certain degree of pollution, such as the emission of harmful gases and the generation of solid waste. Furthermore, as high-performance materials, their cost is relatively high, increasing the production cost of automobiles.

[0006] In summary, existing technologies for multi-cell thin-walled energy-absorbing boxes suffer from problems such as high material consumption and high manufacturing costs; the manufacturing process of induced structure energy-absorbing boxes may generate a certain amount of residual waste, resulting in resource waste; and the filling materials such as aluminum foam, polyurethane foam, and honeycomb materials cause a certain degree of pollution during the manufacturing process of energy-absorbing boxes. Summary of the Invention

[0007] The purpose of this invention is to provide a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings, in order to solve the technical problems of existing energy-absorbing boxes having high material consumption, high manufacturing costs, and residual waste and pollution during the manufacturing process. This invention uses metal shavings to fill the energy-absorbing box, which on the one hand realizes the recycling of metal shavings, avoids resource waste, reduces the manufacturing cost of energy-absorbing boxes, and on the other hand does not pollute the environment during the production process.

[0008] To achieve the above objectives, the present invention employs the following technical solution:

[0009] This application discloses a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings, including the following steps:

[0010] Pre-treat the metal shavings;

[0011] The pretreated metal scraps are pressure-shaped according to the size of the energy-absorbing box, and the porosity of the metal scraps is controlled according to the pressure.

[0012] The shaped metal shavings are then filled into the car's energy-absorbing box.

[0013] Furthermore, the specific steps for pretreating the metal shavings are as follows:

[0014] Screening of metal shavings;

[0015] The sieved metal shavings are then cleaned and dried.

[0016] Furthermore, the specific steps for sieving the metal scraps are as follows:

[0017] They are classified according to the shape, size, and material of the metal scraps.

[0018] Furthermore, in the step of classifying metal scraps according to their shape, size, and material, the classification according to shape is as follows:

[0019] Metal scraps are classified according to their shape into spiral, long coil, flake, and other types.

[0020] Furthermore, in the step of cleaning and drying the screened metal scraps, the specific process of cleaning the metal scraps is as follows:

[0021] Pour the cleaning agent into the cleaning tank of the ultrasonic cleaner, ensuring that the cleaning agent completely covers the metal shavings;

[0022] Use an ultrasonic cleaner to clean the metal shavings, and perform the cleaning cycle at least twice.

[0023] Furthermore, in the step of cleaning and drying the screened metal shavings, after the metal shavings are dried, they are subjected to rust and oxidation prevention treatment.

[0024] Furthermore, the method for pressure shaping the pretreated metal scraps according to the size of the energy-absorbing box, and controlling the porosity of the shaped metal scraps according to the pressure, is as follows:

[0025] The metal shavings are placed in a shaping container and compressed and shaped using a press.

[0026] Applying a set pressure according to the material and shape of the metal scrap causes the compressed and shaped metal scrap to produce different porosities;

[0027] Once a constant pressure value is reached, maintain it for at least twenty minutes to allow the metal shavings to stabilize and be shaped.

[0028] Furthermore, the shaped metal shavings are filled into the car's energy-absorbing box. After the energy-absorbing box is impacted, the metal shavings will be compacted. The compacted filling material is then reprocessed into metal shavings of different shapes or sizes using machining equipment and reused as filling material.

[0029] Based on the above method, the present invention also discloses an automotive energy-absorbing box, including an energy-absorbing box body, the energy-absorbing box body being filled with metal shavings, and the method of filling the energy-absorbing box body with metal shavings adopting a green and environmentally friendly filling method of filling the automotive energy-absorbing box with metal shavings.

[0030] Furthermore, the energy-absorbing box body has a circular or square structure.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. This invention pre-treats metal shavings, then pressure-shapes the pre-treated shavings before filling them into an energy-absorbing box, significantly improving the box's mechanical properties. Pre-treatment facilitates the recycling and reuse of the metal shavings, while also removing contaminants to prevent corrosion. Furthermore, pressure-shaping the pre-treated shavings according to the box's dimensions ensures proper filling and adequate contact between the shaped shavings and the box, enhancing performance. Controlling the porosity of the shaped shavings based on pressure further improves performance. This invention uses metal shavings generated during machining as filler material in automotive energy-absorbing boxes, effectively reducing the cost of commonly used foam fillers and lowering manufacturing costs. It also provides a green and pollution-free solution for recycling and reusing machining-grade metal shavings. Moreover, the metal shavings used as filler can be reused after impact through machining, achieving low-energy, green recycling.

[0033] 2. The present invention cleans and dries the sieved metal shavings to prevent them from corroding the surface of the energy-absorbing box due to impurities when used as filling material.

[0034] 3. In the pretreatment process of metal shavings in this invention, the shavings are classified according to their shape, size, and material. Through structural screening, corresponding structures are selected according to requirements to manufacture energy-absorbing box fillers. The use of identical structures helps improve the overall mechanical stability of the shaped metal shavings. This stability helps maintain the integrity of the energy-absorbing box during collisions. Furthermore, size classification facilitates the optimization of energy distribution within the energy-absorbing box. Specifically, larger metal shavings can absorb more impact energy, while smaller metal shavings can disperse energy over a wider area, thereby reducing local stress concentration. Through size classification, metal shavings of different sizes are then selected according to requirements to process into energy-absorbing box filler components. Finally, material classification is also crucial. Different metal materials have different physical and chemical properties, such as strength, toughness, and corrosion resistance. By selecting suitable metal materials to make the filler, the performance requirements of the energy-absorbing box under different working conditions can be met.

[0035] 4. After drying the metal shavings, the present invention performs anti-rust and anti-oxidation treatment on the dried metal shavings, thereby forming a protective film on the surface of the metal shavings, preventing oxidation and corrosion, extending the service life of the metal shavings, and ensuring the stability of the energy-absorbing box.

[0036] 5. Compared with energy-absorbing boxes without fillers, the energy-absorbing box of this invention has better mechanical properties, realizes the recycling of metal scraps, avoids resource waste, and solves the problem of pollution caused by fillers such as aluminum foam, polyurethane foam and honeycomb materials during the manufacturing process of energy-absorbing boxes. Attached Figure Description

[0037] Figure 1 This is a flowchart illustrating a method according to an embodiment of the present invention;

[0038] Figure 2 This is a diagram illustrating the metal scrap recycling process according to an embodiment of the present invention;

[0039] Figure 3 Mechanical response diagrams of axial crushing experiments on AA6063-T6 circular tubes filled with different metal scraps according to embodiments of the present invention;

[0040] Figure 4 Axial crushing displacement-energy curves of AA6063-T6 circular tubes filled with different metal scraps according to embodiments of the present invention;

[0041] Figure 5 This is a flowchart of the method of the present invention. Detailed Implementation

[0042] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of 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 skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0043] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0044] The present invention will now be described in further detail with reference to the accompanying drawings:

[0045] See Figure 5 This invention discloses a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings, comprising the following steps:

[0046] S1. Pre-treat the metal shavings as follows:

[0047] The metal shavings are sieved as follows:

[0048] Classifying metal scraps according to shape, size, and material is beneficial for improving the overall mechanical stability of the shaped scraps. Since different shaped scraps exhibit different deformation modes and energy dissipation mechanisms upon impact, scraps of specific shapes can form a stable support structure within the filler, enhancing the overall structural stability of the energy-absorbing box. This stability helps maintain the integrity of the energy-absorbing box during collisions. Furthermore, size classification facilitates optimized energy distribution within the energy-absorbing box. Specifically, larger scraps absorb more impact energy, while smaller scraps disperse energy over a wider area, reducing localized stress concentration. Size classification allows for the selection of different sized scraps to be processed into energy-absorbing box filling components according to requirements. Finally, material classification is also crucial. Different metal materials possess different physical and chemical properties, such as strength, toughness, and corrosion resistance. By selecting appropriate metal materials for the filler, the performance requirements of the energy-absorbing box under various operating conditions can be met.

[0049] Preferably, in the step of classifying metal scraps according to their shape, size, and material, the classification according to the shape of the metal scraps is as follows:

[0050] Metal scraps are classified according to their shape into spiral, long coil, flake, and other types.

[0051] The sieved metal shavings are then cleaned and dried, as follows:

[0052] Pour the cleaning agent into the cleaning tank of the ultrasonic cleaner, ensuring that the cleaning agent completely covers the metal shavings;

[0053] Use an ultrasonic cleaner to clean the metal shavings, and perform the cleaning cycle at least twice.

[0054] Preferably, after drying the metal shavings, the dried metal shavings are subjected to rust and oxidation prevention treatment. This forms a protective film on the surface of the metal shavings, which effectively isolates the metal from external corrosive media such as oxygen and water, thereby preventing oxidation and corrosion of the metal shavings, extending their service life, and ensuring the stability of the energy-absorbing box.

[0055] S2. The pretreated metal chips are pressure-shaped according to the size of the energy-absorbing box, and the porosity of the metal chip shaping is controlled according to the pressure.

[0056] Preferably, the method for pressure-shaping the pretreated metal chips according to the size of the energy-absorbing box, and controlling the porosity of the shaped metal chips according to the pressure, is as follows:

[0057] The metal shavings are placed in a shaping container and compressed and shaped using a press.

[0058] Applying a set pressure according to the material and shape of the metal scrap causes the compressed and shaped metal scrap to produce different porosities;

[0059] Once a constant pressure value is reached, maintain it for at least twenty minutes to allow the metal shavings to stabilize and be shaped.

[0060] S3. Fill the shaped metal shavings into the car's energy-absorbing box.

[0061] Preferably, the shaped metal shavings are filled into the car's energy-absorbing box. After the energy-absorbing box is impacted, the filled metal shavings are compacted. The compacted filling material is then reprocessed into metal shavings of different shapes or sizes using machining equipment and reused as filling material.

[0062] See Figure 5 In another feasible embodiment of the present invention, the following modifications are made as appropriate. The steps include:

[0063] Pre-treating metal scraps facilitates their recycling and reuse.

[0064] The pre-treated metal scraps are pressure-shaped according to the size of the energy-absorbing box, which facilitates the filling of the box and ensures full contact between the shaped scraps and the box, thus improving the performance of the energy-absorbing box. Furthermore, the porosity of the shaped metal scraps is controlled according to the pressure applied, further enhancing the performance of the energy-absorbing box.

[0065] The shaped metal shavings are then filled into the car's energy-absorbing box, completing the fabrication of the metal-filled car energy-absorbing box. See [link / reference]. Figure 3 and Figure 4 The energy-absorbing box of the present invention has strong energy-absorbing box performance.

[0066] This invention uses metal shavings generated during machining as filling material in automotive energy-absorbing boxes. Compared to commonly used aluminum foam as filling material, metal shavings can increase the total energy absorbed and effectively reduce the cost of currently used foam-based filling materials. Furthermore, using metal shavings to fill automotive energy-absorbing boxes solves the problem of recycling and reusing machining metal shavings in a green and pollution-free way. Simultaneously, the metal shavings used as filling material can be reused through machining and other methods after impact use, achieving low-energy, green recycling and reuse of metal shavings.

[0067] Example 1:

[0068] See Figure 1 This invention discloses a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings. This invention innovatively integrates metal shavings generated during machining with the filling material of automotive energy-absorbing boxes, realizing the reuse of waste materials.

[0069] A green and pollution-free design method for using metal shavings generated during machining as filling material for automotive energy-absorbing boxes includes the following steps:

[0070] S1. Collection of metal chips from machining:

[0071] The metal shavings are classified according to the processed material and their shape and size. Then, the coolant or other impurities adhering to the surface of the metal shavings are cleaned and dried to prevent them from corroding the surface of the energy-absorbing box due to impurities. Finally, the metal shavings are treated with rust prevention and oxidation prevention.

[0072] S2. Metal chip shaping:

[0073] The collected metal scraps are pressure-molded according to the dimensions of the energy-absorbing box. The metal scraps are placed in a molding die, and different pressures are applied using a pressure testing machine to create metal scrap filling materials with different porosities. When using metal scraps of the same material, shape, and size to manufacture the filling material, the pressure is controlled by maintaining a constant value in the pressure testing machine, and this constant value is used as the standard for manufacturing the filling material.

[0074] S3. Metal shavings filling material is used to fill the automotive energy-absorbing box:

[0075] The shaped metal shavings are filled into the car's energy-absorbing box as its filling material. During the impact, the metal shavings and the thin-walled energy-absorbing box interact and restrain each other, effectively improving the impact resistance of the energy-absorbing box.

[0076] S4. Reuse of metal shavings after impact with the energy-absorbing box:

[0077] Upon impact, the energy-absorbing box absorbs energy through its own plastic deformation. The shaped metal shavings used as filler material are compacted after impact. The compacted filler material is then reprocessed into metal shavings of different shapes or sizes using machining equipment such as machine tools. Through the above steps S1 to S3, the filler material can be reused.

[0078] Example 2:

[0079] See Figure 1 This invention discloses a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings, comprising the following steps:

[0080] S1. Collection of metal chips from machining:

[0081] Metal shavings generated during machining processes such as turning, milling, and planing are collected and classified according to the processed material and the shape and size of the shavings. Then, coolant or other impurities adhering to the surface of the shavings are cleaned to prevent corrosion of the energy-absorbing box surface due to impurities. Finally, the shavings are dried in a drying oven, and then treated with rust and oxidation prevention measures. Figure 2 The data includes metal shavings from three different materials: 5052 aluminum alloy, 2A12-T4 aluminum alloy, and 6061-T6 aluminum alloy. The shapes of these three materials' metal shavings are spiral, long coil, and thin sheet, respectively.

[0082] S2. Metal chip shaping:

[0083] The collected metal shavings are pressure-shaped according to the dimensions of the energy-absorbing box. The metal shavings are placed in a molding die and compressed using a press. Different pressures are applied based on the material and shape of the metal shavings to create different porosities after compression. Once a constant pressure value is reached, it is maintained for a period of time to allow the metal shavings to stabilize.

[0084] S3. Metal shavings filling material is used to fill the automotive energy-absorbing box:

[0085] The shaped metal shavings are filled into the car's energy-absorbing box as its filling material. During the impact, the metal shavings and the thin-walled energy-absorbing box interact and restrain each other, effectively improving the impact resistance of the energy-absorbing box.

[0086] S4. Reuse of metal shavings after impact with the energy-absorbing box:

[0087] Upon impact, the energy-absorbing box absorbs energy through its own plastic deformation. The shaped metal shavings used as filler material are compacted after impact. The compacted filler material is then reprocessed into metal shavings of different shapes or sizes using machining equipment such as machine tools. Through the above steps S1 to S3, the filler material can be reused.

[0088] Example 3:

[0089] See Figure 1 This invention discloses a green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal shavings, comprising the following steps:

[0090] This embodiment uses an AA6063-T6 round tube with a thickness of 0.5 mm and a diameter of 30 mm as an example. It is cut into 80 mm high sections using a laser cutting machine. Spiral 5052 aluminum alloy shavings, long rolls of 2A12-T4 aluminum alloy shavings, and thin sheet-like 6061-T6 aluminum alloy shavings, as well as a mixture of 5052 and 6061-T6 shavings generated during machining, are selected as filler materials. These materials are pressure-shaped under 2500 N pressure. The shaped shavings are then filled into the AA6063-T6 round tube and crushed axially at a speed of 5.4 mm / min. The crushing result is shown below. Figure 3 and Figure 4 As shown, the mechanical response and displacement-energy curves of AA6063-T6 circular tubes filled with different types of metal scraps are presented in the axial crush test. Compared with no filling, using metal scraps as filling material can significantly increase the total energy absorption. Specifically, 5052 metal scraps increased by 171.689%, 5052+6061-T6 metal scraps increased by 75.205%, 2A12-T4 metal scraps increased by 45.174%, and 6061-T6 metal scraps increased by 26.209%.

[0091] Based on the above method, this invention also discloses an automotive energy-absorbing box, including an energy-absorbing box body filled with metal shavings. The method of filling the energy-absorbing box body with metal shavings employs a green and environmentally friendly filling method. Compared to energy-absorbing boxes without fillers, the energy-absorbing box of this invention has better mechanical properties and achieves the recycling of metal shavings, avoiding resource waste. It also solves the problem of pollution associated with the manufacturing process of energy-absorbing boxes using filling materials such as aluminum foam, polyurethane foam, and honeycomb materials.

[0092] Example 4:

[0093] This embodiment discloses an automotive energy-absorbing box, including an energy-absorbing box body, which is filled with metal shavings. The method of filling the energy-absorbing box body with metal shavings is a green and environmentally friendly filling method that uses metal shavings to fill the automotive energy-absorbing box.

[0094] Preferably, the energy-absorbing box body has a circular or square structure.

[0095] Metal processing, including turning, milling, and planing, generates metal chips of various shapes and sizes, such as long coils, spirals, arcs, flocculents, and flakes. These metal surfaces are often covered with coolant oil. Failure to recycle these metal chips results in significant waste and environmental pollution. Traditional smelting or powder metallurgy methods for recycling are complex and generate substantial amounts of waste gas, further polluting the environment. Therefore, finding a rational way to recycle these metal chips without wasting resources or causing environmental pollution is a pressing issue and challenge for companies in the machining and related industries.

[0096] This invention uses metal shavings generated during machining as filler material in automotive energy-absorbing boxes. This effectively reduces the cost of commonly used foam-based filler materials and provides a green, pollution-free solution for recycling and reusing machining metal shavings. Furthermore, the metal shavings used as filler material can be reused through machining and other methods after impact use.

[0097] In summary, compared with the prior art, the present invention has the following beneficial effects:

[0098] A. This invention can utilize the metal shavings generated in most machining processes, and use these shavings as filling material in automotive energy-absorbing boxes to effectively solve the problem of machining metal shavings recycling.

[0099] B. This invention can effectively reduce the cost of filling materials for automotive energy-absorbing boxes, as well as the pollution and losses generated during the manufacturing process of currently popular filling materials.

[0100] C. The filler material used in this invention can be reused.

[0101] D. This invention is environmentally friendly and is a green, low-energy-consumption, and pollution-free energy-absorbing box filling material design method, which includes a complete life-cycle service process of metal scrap from recycling to reuse to remanufacturing to reuse.

[0102] The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solution based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. A green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal scraps, characterized in that, Includes the following steps: The metal shavings are pretreated and classified according to their shape, size, and material. Metal scraps are classified according to their shape into spiral, long coil, and flake types. The pretreated metal scraps are pressure-shaped according to the size of the energy-absorbing box, and the porosity of the shaped metal scraps is controlled according to the pressure, as follows: The metal shavings are placed in a shaping container and compressed and shaped using a press. Applying a set pressure according to the material and shape of the metal scrap causes the compressed and shaped metal scrap to produce different porosities; Once a constant pressure value is reached, maintain it for at least twenty minutes to allow the metal shavings to stabilize and be shaped. The shaped metal shavings are then filled into the car's energy-absorbing box.

2. The green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal scraps according to claim 1, characterized in that, The specific steps for pretreating the metal scraps are as follows: Screening of metal shavings; The sieved metal shavings are then cleaned and dried.

3. The green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal scraps according to claim 2, characterized in that, The specific steps for cleaning and drying the sieved metal scraps are as follows: Pour the cleaning agent into the cleaning tank of the ultrasonic cleaner, ensuring that the cleaning agent completely covers the metal shavings; Use an ultrasonic cleaner to clean the metal shavings, and perform the cleaning cycle at least twice.

4. The green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal scraps according to claim 2, characterized in that, In the step of cleaning and drying the screened metal shavings, after the metal shavings are dried, they are subjected to rust and oxidation prevention treatment.

5. The green and environmentally friendly filling method for filling automotive energy-absorbing boxes with metal scraps according to claim 1, characterized in that, The process involves filling the shaped metal shavings into the car's energy-absorbing box. After an impact, the metal shavings are compacted. The compacted filling material is then reprocessed into metal shavings of different shapes or sizes using machining equipment and reused as filling material.

6. An energy-absorbing box for automobiles, characterized in that, The device includes an energy-absorbing box body, which is filled with metal shavings. The method of filling the energy-absorbing box body with metal shavings is the green and environmentally friendly filling method of filling the automotive energy-absorbing box with metal shavings as described in any one of claims 1 to 5.

7. The automotive energy-absorbing box according to claim 6, characterized in that, The energy-absorbing box body has a circular or square structure.

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