Body components, their manufacturing methods, and vehicles

Abstract

This invention provides a vehicle body component, its manufacturing method, and a vehicle. The vehicle body component includes a first component and a second component connected together. Both the first and second components are made of composite materials and have multiple layers stacked on top of each other. Each component has a connecting portion located in a connection region between them, and a body portion located outside the connecting portion. The layers in each body portion are cured together, and in the connection region, the layers in two connecting portions are staggered and cured together. This invention enables the composite material vehicle body component to achieve a seamless appearance, helping to enhance the visual refinement of the component and improve the overall vehicle appearance quality.

Description

Technical Field

[0001] This invention relates to the field of vehicle body technology, and particularly to a vehicle body component. The invention also relates to a method for manufacturing the aforementioned vehicle body component, and a vehicle using the aforementioned vehicle body component. Background Technology

[0002] With technological advancements and increasingly stringent requirements for energy conservation and emission reduction, lightweight vehicle design has become a crucial aspect of enhancing competitiveness. Consequently, a growing number of automakers are experimenting with new materials and structural processes to reduce the overall weight of their vehicles.

[0003] Currently, the application of composite materials such as carbon fiber has gradually become an important measure for lightweight vehicle body design. In particular, carbon fiber composite materials, which are new materials with excellent mechanical properties transformed from organic fibers through a series of heat treatments, have begun to be used in many vehicle models.

[0004] Taking vehicle body panels made of carbon fiber composite materials as an example, such as the side panels and roof panels in the vehicle body, there are generally two ways to connect them. One method is to apply adhesive to the overlapping area of ​​the roof panel after positioning the side panel, and then bond the roof panel to the side panel. The other method is to deepen the overlapping area of ​​the side panel and roof panel in the Z-direction (vertical direction of the entire vehicle) and further add a roof trim strip to seal the recessed structure formed by the deepening.

[0005] While both methods can connect the side panel and roof panel, the first method results in a visible seam between the two components after curing due to shrinkage of the adhesive during curing. This seam is unsightly and prone to dust accumulation. The second method requires a deeper finish, occupying more Z-axis space, which not only hinders the interior layout of the roof panel and increases component costs, but also leaves a visible seam, contributing to an unsightly appearance and making the seam prone to dust accumulation. Summary of the Invention

[0006] In view of this, the present invention aims to provide a vehicle body component that enables a seamless appearance to be achieved for vehicle body components made of composite materials.

[0007] To achieve the above objectives, the technical solution of the present invention is implemented as follows:

[0008] A vehicle body component includes a first component and a second component connected together. Both the first component and the second component are made of composite materials and have multiple layers stacked together. Both the first component and the second component have a connecting portion located in a connecting area between them, and a body portion located outside the connecting portion.

[0009] The layers in each of the body portions are cured together, and in the connection area, the layers in the two connection portions are staggered and cured together.

[0010] Furthermore, the width k of each of the connecting portions along the connection direction between the first component and the second component is between 25 and 75 mm.

[0011] Furthermore, in the connection area, the plies in the two connection portions are spliced ​​one-to-one, and the seams between adjacent plies are staggered in the connection direction of the first component and the second component.

[0012] Furthermore, the width t of the seam along the connection direction between the first component and the second component is not greater than 1 mm; and / or,

[0013] The distance L between the seams of adjacent layers in the connection direction of the first component and the second component is not less than 25 mm.

[0014] Furthermore, both the first component and the second component are made of carbon fiber composite material.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] The vehicle body component of the present invention is connected by interlacing and splicing layers in the connecting part of the first component and the second component and then curing them together. This allows the two components to be connected, enabling the vehicle body component made of composite material to achieve a seamless appearance at the connection point, thereby helping to improve the visual refinement of the vehicle body component and enhance the overall appearance quality of the vehicle.

[0017] Furthermore, setting the width k of each connecting part ensures the reliability of the connection between the two components. The plies in the two connecting parts are spliced ​​one-to-one, and the seams between adjacent plies are staggered. This not only achieves staggered splicing between the two connecting parts, but also allows the plies in the two connecting parts to have better contact, thereby further ensuring the reliability of the connection between the two components.

[0018] Furthermore, setting the joint width 't' allows for dimensional deformation space during curing of the ply, while also ensuring the contact area between adjacent ply layers, thus improving the connection reliability between the two components. Setting the distance 'L' between adjacent joints reduces the impact of the joint position on the connection strength between the staggered ply layers, also contributing to improved connection reliability between the two components. Both the first and second components utilize carbon fiber composite materials, a mature technology with low cost, and can meet the structural performance requirements of vehicle body components.

[0019] Another object of the present invention is to provide a method for manufacturing a vehicle body component, the method comprising:

[0020] A first component and a second component, each having a body portion and a connecting portion, are respectively molded. The first component and the second component are both made of composite materials and have multiple layers stacked together, and the layers in each body portion are cured together.

[0021] The first and second components are placed in a mold, and after the layers in the two connecting parts are staggered and spliced, the two connecting parts are cured and connected together.

[0022] Furthermore, both the first component and the second component are made of carbon fiber composite material;

[0023] The plies in the two connecting parts are spliced ​​one-to-one, the seams between adjacent plies are staggered in the connection direction of the first component and the second component, and resin is applied to each ply after splicing.

[0024] The two connecting parts are joined by baking and curing with a heater.

[0025] Furthermore, both the first component and the second component are attached to the mold on one side, and a vacuum bag with an air nozzle is laid on the other side of the first component and the second component;

[0026] Both the main body of the first component and the second component are provided with sealing strips between themselves and the mold and the vacuum bag. After vacuuming through the air nozzle, the two connected parts after splicing are baked and cured.

[0027] Furthermore, on the side of the two connecting portions facing the vacuum bag, an isolation mold and a breathable patch are sequentially provided in the direction pointing towards the vacuum bag; and / or,

[0028] A release liner is provided between the first component and the second component and the mold; and / or,

[0029] The heater is an infrared heater.

[0030] The method for preparing the vehicle body parts of the present invention involves first forming a first part and a second part having a body part and a connecting part, and then interlacing and splicing the layers in the connecting part of the two parts and curing them together. This allows the two parts to be connected, enabling the vehicle body parts made of composite materials to achieve a seamless appearance at the connection point, which helps to improve the visual refinement of the vehicle body parts and enhance the overall appearance quality of the vehicle.

[0031] Furthermore, the present invention also proposes a vehicle having the body components described above.

[0032] The vehicle of the present invention has the same beneficial effects as the above-described body parts, and will not be described again here. Attached Figure Description

[0033] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0034] Figure 1 This is a schematic diagram of the structure of the vehicle body component described in an embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of the structure of the first component according to an embodiment of the present invention;

[0036] Figure 3 This is a schematic diagram illustrating the fabrication process of the vehicle body component described in an embodiment of the present invention;

[0037] Explanation of reference numerals in the attached figures:

[0038] 1. First component; 2. Second component; 3. Mold; 4. Sealing strip; 5. Release cloth; 6. Vacuum bag; 7. Separating film; 8. Breathable tape; 9. Air nozzle; 10. Heater;

[0039] 1a, First body part; 1b, First connecting part; 2a, Second body part; 2b, Second connecting part; c, Ply; f, Joint; k, Width of connecting part; t, Width of joint; L, Distance between joints. Detailed Implementation

[0040] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0041] In the description of this invention, it should be noted that the use of terms such as "upper," "lower," "inner," and "outer," indicating orientation or positional relationship, is based on the orientation or positional relationship shown in the accompanying drawings and is only for the convenience of describing the invention and simplifying the description. It does not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the use of terms such as "first" and "second" is also for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0042] Furthermore, in the description of this invention, unless otherwise explicitly defined, the terms "installation," "connection," "joining," and "connector" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention in light of the specific circumstances.

[0043] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0044] Example 1

[0045] This embodiment relates to a vehicle body component, combined with... Figure 1 As shown, the body component includes a first component 1 and a second component 2 connected together. Both the first component 1 and the second component 2 are made of composite materials and have multiple layers c stacked together. Both the first component 1 and the second component 2 also have a connecting portion located in the connecting area Q between them, and a body portion located outside the connecting portion.

[0046] The lay-up c in the main body portion of the first component 1 and the second component 2 are cured together, and in the connection area Q, the lay-up c in the connection portion of the first component 1 and the second component 2 are staggered and cured together, thereby realizing the connection of the first component 1 and the second component 2 to form the body component of this embodiment.

[0047] As shown in the above structure, the first component 1 and the second component 2 are connected by interlacing and solidifying the layers c in the connecting part. This allows the first component 1 and the second component 2 to be connected. In this embodiment, the body parts made of composite materials can achieve a seamless appearance at the connection position, which is beneficial to improving the appearance quality of the body parts.

[0048] Based on the above overview, in detail, as a preferred embodiment, the vehicle body components of this embodiment can be made of carbon fiber composite materials, that is, both the first component 1 and the second component 2 mentioned above are made of carbon fiber composite materials. This allows the use of carbon fiber composite materials for the first component 1 and the second component 2, which has the advantages of mature technology and low cost, while also meeting the structural performance requirements of the vehicle body components.

[0049] Of course, in addition to carbon fiber composite materials, the first component 1 and the second component 2 constituting the vehicle body parts in this embodiment can also be made of other composite materials, as long as they also have multiple layers c in a stacked arrangement, and the connection between different components is achieved through a curing process, as well as the corresponding structural shape of the components.

[0050] In this embodiment, also as a preferred implementation, the vehicle body component formed by connecting the first component 1 and the second component 2 can be, for example, a body panel in the vehicle body. In this case, the aforementioned body panel can be, for example, an exterior body panel composed of a side panel and a roof panel connected together in the vehicle body. Thus, the first component 1 and the second component 2 are respectively the side panel and the roof panel. Furthermore, by adopting the structural design of this embodiment, the effect of no visible seam at the connection point between the side panel and the roof panel can be achieved.

[0051] Of course, it should be noted that, in addition to the vehicle body exterior panels which can be composed of side panel outer panels and roof panel outer panels, the vehicle body component in this embodiment can also be other structures that serve as vehicle body exterior panels. Moreover, besides being a vehicle body panel, the vehicle body component in this embodiment can also be other structures in the vehicle that can be made of carbon fiber composite materials, and this embodiment is not limited to them.

[0052] In this embodiment, for ease of description, the body part and the connecting part in the first component 1 are specifically referred to as the first body part 1a and the first connecting part 1b. Similarly, the body part and the connecting part in the second component 2 are also referred to as the second body part 2a and the second connecting part 2b.

[0053] Furthermore, continue to combine Figure 2 As shown in the figure, as a preferred embodiment, taking the first connecting portion 1b in the first component 1 as an example, the width k of each connecting portion in this embodiment along the connection direction of the first component 1 and the second component 2 can generally be set between 25-75mm.

[0054] At this time, the connection direction between the first component 1 and the second component 2 is that... Figure 1 The width k of each connecting part is set to ensure the reliability of the connection between the first component 1 and the second component 2. Furthermore, in specific implementations, based on the number of ply c in the first component 1 and the second component 2, the width k can be, for example, 25mm, 30mm, 32mm, 35mm, 40mm, 45mm, 50mm, 55mm, 60mm, 65mm, 70mm, 75mm, etc. When the number of ply c is large, the width k should also be large; when the number of ply c is small, the width k should be small accordingly.

[0055] Still Figure 1 As shown in the figure, in a preferred embodiment, the plies c in the first connecting portion 1b and the second connecting portion 2b in the connecting region Q are specifically spliced ​​in a one-to-one correspondence, and the seams f between adjacent plies c are staggered in the connecting direction of the first component 1 and the second component 2.

[0056] Thus, it can be understood that by splicing the plies c in the two connecting parts in a one-to-one correspondence and by staggering the seams f between adjacent plies c, not only can the staggered splicing between the two connecting parts be achieved, but it can also make the plies c in the two connecting parts contact better, thereby further ensuring the reliability of the connection between the first component 1 and the second component 2.

[0057] Of course, it should be noted that, in addition to the preferred method of splicing the plies c in the two connecting parts in a one-to-one correspondence, in specific implementation, based on the specific circumstances such as the thickness of the plies c, it is also possible to stack two or more plies c in one connecting part and then stagger them with multiple plies c that have been stacked in the same way in another connecting part.

[0058] In this embodiment, see still Figure 1 In a preferred embodiment, the width t of the joint f along the connection direction of the first component 1 and the second component 2 can generally be set to no more than 1 mm. In this case, by setting the width t of the joint f, space for dimensional deformation during curing of the layup c can be reserved, while also ensuring the contact area between adjacent layups c, so as to better improve the connection reliability between the first component 1 and the second component 2.

[0059] In practice, the width t of the seam f can be, for example, 0.5mm, 0.8mm or 1mm, and generally, it is preferred to be 1mm.

[0060] In this embodiment, see still Figure 1 As a preferred embodiment, the distance L of the joint f between adjacent plies c in the connection direction of the first component 1 and the second component 2 should be set to not less than 25 mm.

[0061] In this way, by setting the distance L between adjacent seams f, the impact of the position of seam f on the connection strength between the staggered plies c can be reduced, and it also helps to improve the connection reliability between the first component 1 and the second component 2. In specific implementations, the above-mentioned distance L can be, for example, 25mm, 28mm, 30mm, 32mm, 35mm, etc.

[0062] The specific manufacturing method of the vehicle body component in this embodiment can be further described in Embodiment 2 below.

[0063] In this embodiment, the body parts are joined together by interlacing and curing the layers c in the connecting part of the first part 1 and the second part 2. This allows the two parts to be connected, enabling the body parts made of composite materials to achieve a seamless appearance at the connection point. This helps to enhance the visual refinement of the body parts and improve the overall appearance quality of the vehicle, thus having good practicality.

[0064] Example 2

[0065] This embodiment relates to a method for preparing a vehicle body component. This method is specifically used to prepare the vehicle body component in Embodiment 1. In conjunction with the description in Embodiment 1, the preparation method of this embodiment includes the following steps.

[0066] Step s01: Form a first component 1 and a second component 2, each having a body part and a connecting part.

[0067] As mentioned in Embodiment 1, both the first component 1 and the second component 2 are made of composite materials and have multiple layers c stacked together, and the layers c in each body part are cured together. Preferably, the first component 1 and the second component 2 can also be made of carbon fiber composite material.

[0068] Furthermore, in the specific manufacturing process, when molding the first component 1 and the second component 2 respectively, the layup c used to constitute the first component 1 and the second component 2 is laid out as required, and combined with... Figure 1 and Figure 2 As shown, in the first component 1 and the second component 2, the position of the layup c that serves as the main body part needs to be coated with resin during the laying process, while the position that serves as the connecting part does not need to be coated with resin first.

[0069] Next, after isolating and protecting the ply c position, which serves as the connecting part, the ply c position, which serves as the main body part, can be cured using an autoclave process or HP-RTM (High Pressure-Resin Transfer Molding) process. This completes the curing of the main body parts in the first component 1 and the second component 2, and the connecting part is retained in both components. Furthermore, the ply c position at the connecting part is still in a layable state.

[0070] Step s02: Place the formed first part 1 and second part 2 into the mold 3, and after the lay-up c in the two connecting parts is staggered and spliced, the two connecting parts are solidified and connected together.

[0071] In step s02, specifically, as mentioned in Embodiment 1, it is by... Figure 1 and then combine Figure 3 As shown, preferably, the plies c in the connecting portion of the first component 1 and the second component 2 are spliced ​​one-to-one, and the seams f between adjacent plies c are staggered in the connecting direction of the first component 1 and the second component 2.

[0072] At the same time, as with the cured main body, resin should also be applied to each of the plies c after splicing. In this embodiment, after the plies c in the two connecting parts are staggered, the two connecting parts can be further baked by the heater 10 to accelerate resin curing and achieve a cured connection between the two connecting parts.

[0073] In addition, in step s02, the first component 1 and the second component 2 can generally be positioned on the mold 3 by tooling fixtures, and the mold 3 is usually also provided with a contoured surface made of the appearance surface of the corresponding vehicle model part, so that the required appearance surface can be formed after the connection area Q is cured.

[0074] After positioning it on mold 3, each layer c can be laid out sequentially according to the design drawing, as follows: Figure 3 As shown, the plies c in the two connecting parts are spliced ​​one-to-one, and the seams f between adjacent plies c are staggered in the connection direction of the first component 1 and the second component 2. Of course, during the installation, the width t of the seam f can generally be 1mm, and the distance L between the seams f of adjacent layers can be set to not less than 25mm. At the same time, a layer of resin needs to be applied to each ply c after installation.

[0075] After the first component 1 and the second component 2 are laid out, they are both attached to the mold 3 on one side. Corresponding to the side attached to the mold 3, in this embodiment, a vacuum bag 6 with an air nozzle 9 is laid on the other side of the first component 1 and the second component 2. At the same time, sealing strips 4 are also provided between the main body of the first component 1 and the mold 3 and the vacuum bag 6. With the setting of sealing strips 4 on both sides, a sealed space can be formed at the connection area Q. Therefore, after vacuuming through the air nozzle 9, the heater 10 can be used to bake and cure the two connected parts after splicing.

[0076] It is worth noting that during the actual implementation, when drawing a vacuum through the air nozzle 9, the sealing strip 4 on the side where the vacuum bag 6 is located should be pressed to ensure the sealing effect of the vacuum bag 6. During the process of connecting the air nozzle 9 to the vacuum pump and drawing a vacuum, the vacuum bag 6 should be continuously adjusted to keep it flat, and the connection between the vacuum bag 6 and the sealing strip 4 should be checked for leaks. Once the set vacuum standard is reached, the air nozzle 9 can be closed and the vacuum pump stopped.

[0077] In a preferred embodiment, furthermore, on the side of the two connecting parts facing the vacuum bag 6, an isolation mold 7 and a breathable patch 8 can be sequentially arranged in the direction pointing towards the vacuum bag. The isolation mold 7 and the breathable patch 8 prevent the resin-coated layup c from adhering to the vacuum bag 6 and also ensure the curing effect of the two interlocking connecting parts during heating and baking. In practice, the isolation mold 7 and the breathable patch 8 can both be conventional products used in the manufacture of carbon fiber composite parts.

[0078] Additionally, as a preferred embodiment, a release cloth 5 can also be provided between the first component 1 and the second component 2 and the mold in this embodiment, so as to facilitate the separation of the first component 1 and the second component 2 from the mold 3 after curing. The heater 10 is preferably an infrared heater, and the heating temperature and time of the heater, as well as the vacuum standard during vacuuming, can be specifically selected according to the number of layers in layup c.

[0079] The method for preparing the body parts in this embodiment involves first forming a first part 1 and a second part 2 having a body part and a connecting part, and then interleaving and splicing the lay-up c in the connecting part of the two parts and curing them together. This allows the two parts to be connected, enabling the body parts made of composite materials to achieve a seamless appearance at the connection position, which helps to improve the visual refinement of the body parts and enhance the overall appearance quality of the vehicle.

[0080] Furthermore, it should be noted that after the curing of the connection area Q between the first component 1 and the second component 2 is completed, it can be further polished and finished, and then sprayed on the vehicle to give the vehicle body component prepared in this embodiment a better appearance quality.

[0081] Example 3

[0082] This embodiment relates to a vehicle, which has the body components described in Embodiment 1.

[0083] As mentioned in Embodiment 1, in the vehicle of this embodiment, the aforementioned body components may be, for example, exterior body panels composed of side panels and roof panels. In addition to being exterior body panels, the aforementioned body components may also be other parts in the vehicle made of composite materials, and the composite material is preferably carbon fiber composite material.

[0084] The vehicle in this embodiment uses the body parts in Embodiment 1, which enables the body parts made of composite materials to achieve a seamless appearance at the connection points, helping to enhance the visual refinement of the body parts and thus improving the overall appearance quality of the vehicle.

[0085] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A vehicle body component, characterized in that: It includes a first component (1) and a second component (2) connected together, both of which are made of composite material and have multiple layers (c) stacked together, and both of which have a connecting portion located in a connecting region (Q) between them, and a body portion located outside the connecting portion; The plies (c) in each of the body parts are cured together, and in the connection region (Q), the plies (c) in the two connection parts are staggered and cured together; The width k of each of the connecting portions along the connecting direction of the first component (1) and the second component (2) is between 25-75 mm; In the connection area (Q), the plies (c) in the two connection parts are spliced ​​one-to-one, and the seams (f) between adjacent plies (c) are staggered in the connection direction of the first component (1) and the second component (2); The width t of the seam (f) along the connection direction between the first component (1) and the second component (2) is not greater than 1 mm; The distance L between the joints (f) between adjacent plies (c) in the connection direction between the first component (1) and the second component (2) is not less than 25 mm.

2. The vehicle body component according to claim 1, characterized in that: Both the first component (1) and the second component (2) are made of carbon fiber composite material.

3. A method for manufacturing a vehicle body component according to claim 1, characterized in that, The preparation method includes: A first component (1) and a second component (2) are respectively formed, each having a body portion and a connecting portion, wherein the first component (1) and the second component (2) are both made of composite materials and have multiple layers (c) stacked together, and the layers (c) in each of the body portions are cured together; The first component (1) and the second component (2) are placed in the mold (3), and after the lay-up (c) in the two connecting parts is staggered, the two connecting parts are cured and connected together.

4. The method for manufacturing a vehicle body component according to claim 3, characterized in that: Both the first component (1) and the second component (2) are made of carbon fiber composite material; The plies (c) in the two connecting parts are spliced ​​one-to-one, and the seams (f) between adjacent plies (c) are staggered in the connection direction of the first component (1) and the second component (2), and resin is applied to each ply (c) after splicing. The two connecting parts are baked and cured by a heater (10).

5. The method for manufacturing a vehicle body component according to claim 4, characterized in that: The first component (1) and the second component (2) are both attached to the mold (3) on one side, and a vacuum bag (6) with an air nozzle (9) is laid on the other side of the first component (1) and the second component (2). The main body of the first component (1) and the second component (2) are provided with sealing strips (4) between the mold (3) and the vacuum bag (6), and after vacuuming through the air nozzle (9), the two connected parts after splicing are baked and cured.

6. The method for manufacturing a vehicle body component according to claim 5, characterized in that: The two connecting portions are arranged on one side facing the vacuum bag (6), and an isolation mold (7) and a breathable patch (8) are sequentially provided in the direction pointing towards the vacuum bag; and / or, A release cloth (5) is provided between the first component (1) and the second component (2) and the mold; and / or, The heater (10) is an infrared heater.

7. A vehicle, characterized in that: The vehicle is equipped with the body component as described in claim 1 or 2.

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