Light door module, vehicle door, stamping die of cover plate and injection mold of door module

Abstract

The invention discloses a light door module, a vehicle door, a stamping mold of a cover plate and an injection mold of the door module. The stamping mold comprises a framework and the cover plate; the cover plate is formed by stamping a plate-shaped structure formed by pressing a plurality of layers of glass fiber plates, and the outer contour of the cover plate is matched with a mounting hole in the automobile door inner metal plate. A guide rail mounting part is arranged on the cover plate; a plurality of through holes are formed in the cover plate and used for mounting a plurality of vehicle door accessories; the framework is fixedly connected in the cover plate; the framework is made of non-metal materials in an injection molding mode and comprises a frame part and a guide rail part. The outer contour of the frame part is matched with that of the cover plate, and a plurality of connecting parts are arranged on the frame part or the cover plate along the edge and used for being connected with a metal plate in a vehicle door; the guide rail part is connected between the upper edge and the lower edge of the frame part, and the guide rail part corresponds to and is fixedly connected with the guide rail mounting part. According to the door module, weight reduction and thinning are achieved, and the whole vehicle can have better noise, vibration and sound vibration roughness performance.

Description

Technical Field

[0001] The present application relates to the technical field of vehicle doors, and in particular to a lightweight door module and a vehicle door, a stamping die for a cover plate, and an injection mold for a door module. Background Art

[0002] The door module is one of the important parts in the car door, which is used to install parts such as window glass, speakers and wiring harnesses. In the prior art, the door module is a complex structure made of a composite material of polypropylene and glass fiber, which is integrally injection molded. Since the composite material of polypropylene and glass fiber has poor fluidity, the fluidity and filling properties of the thin-walled area of ​​the complex shape are poor, and thus the demand for further thinning and weight reduction of the door module cannot be met. Summary of the invention

[0003] In order to solve at least one aspect of the above problems, the present invention provides a lightweight door module, including a frame and a cover plate; the cover plate is a plate-like structure formed by pressing several layers of fiberglass boards, and the outer contour of the cover plate matches the mounting holes on the inner sheet metal of the vehicle door; a guide rail mounting portion is provided on the cover plate; a plurality of through holes are opened on the cover plate for installing a plurality of door accessories; the frame is fixedly connected to the cover plate; the frame is injection-molded by non-metallic materials, and the frame includes a frame portion and a guide rail portion; the frame portion matches the outer contour of the cover plate, and a plurality of connecting portions are provided on the frame portion or along the edge of the cover plate for connecting to the inner sheet metal of the vehicle door; the guide rail portion is connected between the upper edge and the lower edge of the frame portion, and the guide rail portion corresponds to and is fixedly connected to the guide rail mounting portion.

[0004] Through the above technical scheme, the cover plate has a simple structure, occupies a large area and is relatively flat. It is made of glass fiber board through stamping, which helps to make the cover plate lighter and thinner; the complex structure of the frame is still made by injection molding, and the cover plate and the frame are fixed together to form the door module of the present application, which can achieve a weight reduction of 15% to 33% and a thinning of 0.5 to 1 mm; and in the modal analysis process, it is found that the door module of the present application has the effect of increasing the first-order mode, so that the whole vehicle has better noise, vibration and acoustic roughness performance.

[0005] Preferably, the fiberglass board comprises a first surface layer, an inner layer and a second surface layer which are sequentially distributed; the first surface layer and the second surface layer are both made of polypropylene particles, the inner layer is made of fiberglass cloth, and the first surface layer and the second surface layer are respectively fixed on two opposite surfaces of the inner layer.

[0006] Preferably, the cover plate has a thickness ranging from 0.3 to 5 mm.

[0007] Preferably, the cover plate has a thickness ranging from 0.5 to 1.5 mm.

[0008] Preferably, the cover plate is heated and softened after being stamped and then integrally injection molded with the frame to achieve the fixed connection between the cover plate and the frame. Through the above technical scheme, a method of fixing the cover plate and the frame is disclosed, in which the stamped cover plate is heated and softened and placed in an injection mold, the material used for the frame is injected into the processing cavity of the frame, and then the cover plate and the frame are cured together, so that a strong interaction force is generated between the cover plate and the frame, and its connection strength, durability and economy are all high.

[0009] Preferably, a reinforcing net is fixedly connected inside the frame portion.

[0010] Preferably, the skeleton further comprises a plurality of mounting rings, which are fixedly connected to the inside of the frame portion. The plurality of mounting rings respectively correspond to and are fixedly connected to the plurality of through holes, thereby improving the strength of the plurality of through holes.

[0011] The present application also provides a lightweight vehicle door, comprising a vehicle door inner sheet metal and a lightweight door module as described above; a penetrating mounting hole is provided at the lower portion of the vehicle door inner sheet metal, and the edge of the frame portion or the cover plate is fixedly or detachably connected to the edge of the mounting hole.

[0012] The present application also provides a stamping die for a cover plate, which is used to produce a cover plate of any of the above-mentioned light door modules, an upper die and a lower die, the bottom surface of the upper die matches the first side surface of the cover plate, and the top surface of the lower die matches the second side surface of the cover plate opposite to the first side surface; a plurality of protrusions are fixedly connected to the top surface of the lower die, and a plurality of pits are provided on the bottom surface of the upper die, and the plurality of protrusions correspond to and match the plurality of pits; the shapes and sizes of the cross sections of the plurality of protrusions respectively match the shapes and sizes of the plurality of through holes, and the positions of the plurality of protrusions distributed on the top surface of the lower die match the positions of the plurality of through holes distributed on the cover plate.

[0013] The present application also provides an injection mold for a door module, which is used to produce any of the above-mentioned lightweight door modules, including an upper mold and a lower mold; the cavity of the upper mold matches the frame, the cavity of the lower mold matches the cover plate, the top surface of the lower mold is coplanar with the bottom surface of the upper mold, and the upper mold and the lower mold are detachably connected.

[0014] The light door module, the door, the cover plate stamping die and the door module injection mold of the present invention have the following characteristics:

[0015] Beneficial effects:

[0016] The present application innovatively designs a door module to include a cover plate stamped from a glass fiber board and a frame injection-molded from a polypropylene mixed long fiber. The cover plate is stamped and then softened by heating and then integrally injection-molded with the frame to achieve fixation between the cover plate and the frame. The cover plate has a simple structure, occupies a large area and is relatively flat. It is made of a glass fiber board by stamping, which helps to make the cover plate lighter and thinner. The frame has a complex structure, and in order to ensure the strength of the door module of the present application, the frame is relatively thick and is suitable for injection molding. Therefore, the door module of the present application achieves weight reduction and thinning while ensuring strength, and helps the entire vehicle have better noise, vibration and acoustic roughness performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to better understand the above and other purposes, features, advantages and functions of the present invention, reference may be made to the embodiments shown in the accompanying drawings. The same reference numerals in the accompanying drawings refer to the same components. It should be understood by those skilled in the art that the accompanying drawings are intended to schematically illustrate the preferred embodiments of the present invention and have no limiting effect on the scope of the present invention, and the components in the drawings are not drawn to scale.

[0018] Figure 1 It shows a schematic structural diagram of a light door module according to an embodiment of the present invention;

[0019] Figure 2 A schematic structural diagram of a skeleton of a light door module according to an embodiment of the present invention is shown;

[0020] Figure 3 A schematic structural diagram of a cover plate of a lightweight door module according to an embodiment of the present invention is shown.

[0021] Description of reference numerals:

[0022] 1. Frame; 11. Frame portion; 12. Guide rail portion; 13. First mounting ring; 14. Second mounting ring; 15. Third mounting ring; 16. Fourth mounting ring; 17. Fifth mounting ring; 18. Reinforcement net; 2. Cover plate; 21. Guide rail mounting portion; 22. First through hole; 23. Third through hole; 24. Fourth through hole; 25. Fifth through hole; 26. Reinforcement rib; 3. Connection portion. DETAILED DESCRIPTION

[0023] The following is a description of exemplary embodiments of the present disclosure in conjunction with the accompanying drawings, including various details of the embodiments of the present disclosure to facilitate understanding, which should be considered as merely exemplary. Therefore, it should be recognized by those of ordinary skill in the art that various changes and modifications may be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, descriptions of well-known functions and structures are omitted in the following description.

[0024] As used herein, the term "including" and its variations mean open inclusion, i.e., "including but not limited to". Unless otherwise stated, the term "or" means "and / or". The term "based on" means "based at least in part on". The terms "an example embodiment" and "an embodiment" mean "at least one example embodiment". The term "another embodiment" means "at least one additional embodiment". The terms "first", "second", etc. may refer to different or the same objects. Other explicit and implicit definitions may also be included below.

[0025] In order to at least partially solve one or more of the above-mentioned problems and other potential problems, an embodiment of the present disclosure proposes a lightweight door module, including a frame 1 and a cover plate 2; the cover plate 2 is a plate-like structure formed by pressing several layers of fiberglass boards, and the outer contour of the cover plate 2 matches the mounting holes on the inner sheet metal of the vehicle door; a guide rail mounting portion 21 is provided on the cover plate 2; a plurality of through holes are opened on the cover plate 2 for mounting a plurality of door accessories; the frame 1 is fixedly connected to the cover plate 2; the frame 1 is injection-molded by non-metallic materials, and the frame 1 includes a frame portion 11 and a guide rail portion 12; the frame portion 11 matches the outer contour of the cover plate 2, and a plurality of connecting portions 3 are provided on the frame portion 11 or on the cover plate 2 along its edge for connecting with the inner sheet metal of the vehicle door; the guide rail portion 12 is connected between the upper edge and the lower edge of the frame portion 11, and the guide rail portion 12 corresponds to and is fixedly connected to the guide rail mounting portion 21.

[0026] Specifically, Figures 1 to 3 As shown, the glass fiber board includes a first surface layer, an inner layer and a second surface layer distributed in sequence; the first surface layer and the second surface layer are both made of polypropylene particles, the inner layer is made of glass fiber cloth, the first surface layer and the second surface layer are respectively fixed to the two opposite surfaces of the inner layer, and the cover plate 2 is a plate-like structure formed by pressing a plurality of layers of glass fiber boards. Preferably, the number of layers of the glass fiber boards is 10 to 90, the thickness of the cover plate 2 is in the range of 0.3 to 5 mm, and the preferred thickness range of the cover plate 2 is 0.5 to 1.5 mm; the shape and size of the outer contour of the cover plate 2 are matched with the shape and size of the mounting hole on the inner sheet metal of the vehicle door; a guide rail mounting portion 21 is provided on the cover plate 2, and the guide rail mounting portion 21 includes two mutually parallel mounting groove structures, such as Figure 3 shown.

[0027] The cover plate 2 is provided with a plurality of through holes for installing door accessories. Specifically, the cover plate 2 is provided with a first through hole 22, a second through hole, a third through hole 23, a fourth through hole 24 and a fifth through hole 25; the first through hole 22 is circular or semicircular and is located at the edge of the cover plate 2. When the first through hole 22 is semicircular, the first through hole 22 is connected to the edge of the cover plate 2, so that a semicircular notch structure is formed at the edge of the cover plate 2 for installing a speaker; two second through holes are provided, which are respectively opened near the two mounting grooves, and the two second through holes are on the same horizontal line for disassembling the window glass; the third through hole 23 and the fourth through hole 24 are both opened between the two mounting grooves for installing a motor for driving the window glass and a collision sensor for monitoring the force condition of the door when it is hit sideways; the fifth through hole 25 is opened at the edge of the cover plate 2 for passing the wiring harness; a plurality of reinforcing ribs 26 are fixed inside the cover plate 2.

[0028] The frame 1 is fixedly connected to the cover plate 2. Preferably, the cover plate 2 is stamped and softened, and then integrally injection molded with the frame 1 to achieve the fixed connection between the cover plate 2 and the frame 1. The frame 1 is made of polypropylene mixed with 10% to 50% long glass fiber by injection molding. The thickness of the frame 1 is 0.5 to 5 mm. Preferably, the thickness of the frame 1 is 1 to 3 mm. Figure 2 As shown, the frame 1 is a hollow structure, and the frame 1 includes a frame portion 11, a guide rail portion 12 and a plurality of mounting rings; the shape and size of the frame portion 11 match the shape and size of the outer contour of the cover plate 2, and a plurality of connecting portions 3 are arranged on the frame portion 11 or along the edge of the cover plate 2 for connecting with the inner sheet metal of the door. In this embodiment, the plurality of connecting portions 3 are arranged at the edge of the cover plate 2, such as Figure 3 As shown; the guide rail portion 12 includes two guide rails parallel to each other, the two guide rails are respectively fixed between the upper edge and the lower edge of the frame portion 11, and the two rail portions correspond to and are fixed to the two mounting grooves respectively; preferably, a reinforcing net 18 is fixed inside the frame portion 11, specifically, the reinforcing net 18 is distributed between the two guide rails and between the guide rails and the frame portion 11, and the reinforcing net 18 is fixed to the inner sides of the two guide rails and the edges of the frame portion 11;

[0029] A plurality of mounting rings are fixedly connected to the interior of the frame portion 11, and the plurality of mounting rings correspond to and are fixedly connected to the plurality of through holes, respectively. Specifically, the plurality of mounting rings include a first mounting ring 13, a second mounting ring 14, a third mounting ring 15, a fourth mounting ring 16, and a fifth mounting ring 17; the first mounting ring 13 is circular or semicircular and is located at the edge of the frame portion 11. When the first mounting ring 13 is circular, the outer edge of the first mounting ring 13 is fixedly connected to the inner edge of the frame portion 11 and the reinforcing net 18; when the first mounting ring 13 is semicircular, both ends of the first mounting ring 13 are fixedly connected to the frame portion 11, respectively, so that the frame portion 11 forms a semicircular notch at the first mounting ring 13, such as Figure 2As shown, the first mounting ring 13 corresponds to the first through hole 22, and the edge of the first mounting ring 13 is fixedly connected to the edge of the first through hole 22; two second mounting rings 14 are provided, which are respectively fixed to the reinforcing net 18 near the two guide rails, and the two second mounting rings 14 are on the same horizontal line, and the two second mounting rings 14 correspond to the two second through holes respectively, and the edge of the second mounting ring 14 is fixedly connected to the edge of the second through hole. Preferably, a plug is provided in the structure after the second mounting ring 14 and the second through hole are fixedly connected; the third mounting ring 15 and the fourth mounting ring 16 are respectively fixedly connected between the two guide rails. The fifth mounting ring 17 is fixed to the reinforcing net 18 near the frame portion 11, and the fifth mounting ring 17 corresponds to the fifth through hole 25, and the edge of the fifth mounting ring 17 is fixed to the edge of the fifth through hole 25. Preferably, a sealing ring is provided in the structure after the fifth mounting ring 17 is fixed to the fifth through hole 25, so as to separate the dry area and the wet area.

[0030] The present application also provides a lightweight vehicle door, comprising a vehicle door inner sheet metal and a lightweight door module as described above; a penetrating mounting hole is opened at the lower part of the vehicle door inner sheet metal, and the edge of the frame portion 11 or the cover plate 2 is fixedly or detachably connected to the edge of the mounting hole.

[0031] Preferably, the edge of the frame portion 11 or the cover plate 2 is detachably connected to the edge of the mounting hole, and the connecting portion 3 on the frame portion 11 or the edge of the cover plate 2 is a first hole, in which a buckle is installed; a plurality of second holes are opened at the edge of the mounting hole, and the second holes correspond to the first holes one by one, and the buckle is snapped into the second holes.

[0032] The present application also provides a stamping die for a cover plate, which is used to produce a cover plate 2 of any of the above-mentioned light door modules, including an upper die and a lower die, the bottom surface of the upper die matches the first side surface of the cover plate 2, and the top surface of the lower die matches the second side surface of the cover plate 2 opposite to the first side surface; a plurality of protrusions are fixedly connected to the top surface of the lower die, and a plurality of pits are provided on the bottom surface of the upper die, and the plurality of protrusions and the plurality of pits correspond to and match each other; the shapes and sizes of the cross sections of the plurality of protrusions respectively match the shapes and sizes of the plurality of through holes, and the positions of the plurality of protrusions distributed on the top surface of the lower die match the positions of the plurality of through holes distributed on the cover plate 2.

[0033] The present application also provides an injection mold for a door module, which is used to produce any of the above-mentioned lightweight door modules, including an upper mold and a lower mold; the cavity of the upper mold matches the frame 1, the cavity of the lower mold matches the cover plate 2, the top surface of the lower mold is coplanar with the bottom surface of the upper mold, and the upper mold and the lower mold are detachably connected. Specifically, a plurality of first positioning holes are opened on the upper mold, and a plurality of second positioning holes are opened on the lower mold, and the plurality of first positioning holes correspond to the plurality of second positioning holes, and bolts are simultaneously passed through the corresponding first positioning holes and the second positioning holes to realize the connection between the upper mold and the lower mold.

[0034] The production method of the light door module of the present application is: first, a plate-like structure formed by pressing a multi-layer glass fiber board is cut into a size and shape matching the cover plate 2 by water shearing, and then placed in a stamping mold, and formed into a cover plate 2 by hot stamping; the cover plate 2 is placed in the cavity of the lower mold, the upper mold is installed and the injection mold is preheated, and a mixture of polypropylene and long glass fibers is injected into the cavity of the upper mold, and an integrated door module is formed through heat preservation curing and cooling demolding.

[0035] The embodiments of the present disclosure have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and changes will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The selection of terms used herein is intended to best explain the principles of the embodiments, practical applications, or technical improvements in the market, or to enable other persons of ordinary skill in the art to understand the present invention.

Claims

1. A light door module, characterized in that: It comprises a frame (1) and a cover plate (2); The cover plate (2) is formed by stamping a plate-like structure formed by pressing a plurality of layers of glass fiber boards, and the outer contour of the cover plate (2) matches the mounting hole on the inner sheet metal of the vehicle door; a guide rail mounting portion (21) is provided on the cover plate (2); and a plurality of through holes are provided on the cover plate (2) for mounting a plurality of vehicle door accessories; The frame (1) is fixedly connected to the cover plate (2); the frame (1) is injection-molded by non-metallic materials, and the frame (1) comprises a frame portion (11) and a guide rail portion (12); the frame portion (11) matches the outer contour of the cover plate (2), and a plurality of connection portions (3) are arranged on the frame portion (11) or on the cover plate (2) along its edge, for connection with the sheet metal inside the vehicle door; the guide rail portion (12) is connected between the upper edge and the lower edge of the frame portion (11), and the guide rail portion (12) corresponds to and is fixedly connected to the guide rail mounting portion (21).

2. A lightweight door module according to claim 1, characterized in that: The fiberglass board includes a first surface layer, an inner layer and a second surface layer which are sequentially distributed; the first surface layer and the second surface layer are both made of polypropylene particles, the inner layer is made of fiberglass cloth, and the first surface layer and the second surface layer are respectively fixed on two opposite surfaces of the inner layer.

3. A lightweight door module according to claim 1, characterized in that: The thickness of the cover plate (2) ranges from 0.3 to 5 mm.

4. A lightweight door module according to claim 3, characterized in that: The thickness of the cover plate (2) ranges from 0.5 to 1.5 mm.

5. A lightweight door module according to claim 1, characterized in that: The cover plate (2) is stamped and softened, and then injection-molded integrally with the frame (1), thereby achieving fixed connection between the cover plate (2) and the frame (1).

6. A light door module according to claim 1, characterized in that: A reinforcing net (18) is fixedly connected inside the frame portion (11).

7. A light door module according to claim 1, characterized in that: The frame (1) further comprises a plurality of mounting rings, the plurality of mounting rings being fixedly connected to the interior of the frame portion (11), and the plurality of mounting rings respectively corresponding to and fixedly connected to the plurality of through holes.

8. A light vehicle door, characterized in that: It comprises a door inner sheet metal and a light door module as claimed in any one of claims 1 to 7; a through mounting hole is provided at the lower part of the door inner sheet metal, and the edge of the frame part (11) or the cover plate (2) is fixedly or detachably connected to the edge of the mounting hole.

9. A stamping die for a cover plate, used for producing a cover plate (2) of a light door module according to any one of claims 1 to 7, characterized in that: An upper mold and a lower mold, wherein the bottom surface of the upper mold matches the first side surface of the cover plate (2), and the top surface of the lower mold matches the second side surface of the cover plate (2) opposite to the first side surface; a plurality of protrusions are fixedly connected to the top surface of the lower mold, and a plurality of pits are provided on the bottom surface of the upper mold, and the plurality of protrusions correspond to and match the plurality of pits; the shapes and sizes of the cross sections of the plurality of protrusions respectively match the shapes and sizes of the plurality of through holes, and the positions of the plurality of protrusions distributed on the top surface of the lower mold match the positions of the plurality of through holes distributed on the cover plate (2).

10. An injection mold for a door module, used for producing a light door module according to any one of claims 1 to 7, characterized in that: It comprises an upper mould and a lower mould; the mould cavity of the upper mould matches the frame (1), the mould cavity of the lower mould matches the cover plate (2), the top surface of the lower mould is coplanar with the bottom surface of the upper mould, and the upper mould and the lower mould are detachably connected.

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