Foamed aluminum processing method and vehicle body cavity structure applying same

Abstract

The invention provides a machining method of foamed aluminum and a vehicle body cavity structure applying the machining method. The machining method comprises the following steps that a groove is formed in the surface of the foamed aluminum; a plurality of stress parts are embedded into the foamed aluminum; and an expansion bonding piece is placed in the groove, and the foamed aluminum is bonded to the cavity structure to be filled through the expansion bonding piece. According to the machining method, a groove is formed in foamed aluminum, a stress part is embedded, and an expansion bonding piece is bonded in the groove. After the expansion bonding piece expands, the foamed aluminum and the cavity structure are bonded together, and the stress part on the foamed aluminum provides a stress point for fixed connection between the foamed aluminum and the cavity structure. According to the machining method, the foamed aluminum can be stably and fixedly connected into the cavity structure, it is guaranteed that the filled cavity structure generates counter-acting force when being subjected to force in the two directions of bending and extruding, and the cavity structure has a deformed buffering area.

Description

Technical Field

[0001] The invention relates to the field of foam aluminum processing, and in particular to a foam aluminum processing method and a vehicle body cavity structure using the processing method. Background Art

[0002] Due to its special porous structure, foam aluminum has high specific strength, high specific stiffness, energy absorption, good damping and shock absorption performance, corrosion resistance, high temperature resistance and other properties. In recent years, foam aluminum has officially entered the automotive field. It mainly utilizes the light weight of foam metal and its good energy absorption and buffering performance to improve the anti-collision ability of the car and effectively reduce the damage to the person or object being collided.

[0003] However, since the foaming uniformity of foamed aluminum is difficult to control, the existing production technology can only produce some parts with simple shapes. At present, foamed aluminum is mostly used as a cavity filler for body sheet metal in the research of body applications. However, due to the material properties of foamed aluminum itself, it cannot be connected to other body sheet metals by welding, screwing, etc. The application of foamed aluminum in body design is also limited and cannot be widely used.

[0004] At present, the commonly used connection method of foam aluminum is to make a sandwich plate with foam aluminum sandwiched between two layers of stress-bearing parts, open holes on the sandwich plate to embed sleeves, and then bolt the whole plate to the position where it needs to be installed. In this way, the weight reduction effect of the stress-bearing parts on both sides is not obvious. In addition, the use of steel sleeves will cause electrochemical corrosion problems, and if aluminum sleeves are used, the strength will not meet the requirements. Summary of the invention

[0005] In view of the above shortcomings of the prior art, the present invention provides a method for processing foam aluminum and a vehicle body cavity structure using the processing method, so as to improve the technical problem of poor fixing effect of foam aluminum in the cavity structure in the prior art.

[0006] To achieve the above-mentioned object and other related objects, the present invention provides a method for processing foam aluminum, comprising the following steps:

[0007] A groove is formed on the surface of the foam aluminum;

[0008] Embedding a number of stress-bearing parts into the foamed aluminum;

[0009] An expansion adhesive is placed in the groove, and the foamed aluminum is bonded to the cavity structure to be filled by the expansion adhesive.

[0010] In one example of the present invention, the groove is opened on the surface where the foam aluminum contacts the cavity structure.

[0011] In an example of the present invention, there are a plurality of grooves, and the grooves are at least formed on two opposite surfaces of the foam aluminum.

[0012] In one example of the present invention, the step of embedding a plurality of force-bearing parts into the foamed aluminum includes:

[0013] A plurality of stress-bearing grooves are provided on the foam aluminum;

[0014] The force-bearing part is embedded into the foam aluminum through the force-bearing part groove.

[0015] In one example of the present invention, the processing method further includes: fixing the force-bearing part to the cavity structure to enhance the firmness between the foam aluminum and the cavity structure.

[0016] In one example of the present invention, the steps of placing an expansion adhesive in a groove and bonding the foamed aluminum to the cavity structure to be filled by the expansion adhesive include:

[0017] placing the expansion adhesive member in the groove;

[0018] placing the aluminum foam with the expansion bonding piece placed thereon into the cavity structure to be filled;

[0019] The foam aluminum and the cavity structure are heated to a preset temperature to expand the expansion adhesive and bond the foam aluminum and the cavity structure.

[0020] In one example of the present invention, the area size and thickness of the force-bearing portion match the area and thickness of the foamed aluminum.

[0021] In one example of the present invention, a vehicle body cavity structure is also provided, the vehicle body cavity structure comprising: a cavity structure and foam aluminum, wherein the foam aluminum is filled into the cavity structure; wherein the foam aluminum is processed by any of the processing methods described above.

[0022] In one example of the present invention, the cavity structure and the force-bearing part are fixed by hot-melt self-tapping screws.

[0023] In one example of the present invention, a through hole matching the position of the force-bearing part is opened on the cavity structure; through the through hole, hot-melt self-tapping screws fix the force-bearing part, the foam aluminum and the cavity structure.

[0024] The present invention provides a foam aluminum processing method and a vehicle body cavity structure using the processing method. In the processing method, a groove is opened on the foam aluminum, a force-bearing portion is embedded, and an expansion adhesive is pasted in the groove. After the expansion adhesive expands, the foam aluminum and the cavity structure are bonded together, and the force-bearing portion on the foam aluminum provides a force point for the fixed connection between the foam aluminum and the cavity structure. The processing method enables the foam aluminum to be stably fixedly connected in the cavity structure, ensuring that the filled cavity structure generates a reaction force when subjected to bending and extrusion forces in two directions, and has a deformation buffer area. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0026] Figure 1 This is a flow chart of a foam aluminum processing method according to an embodiment of the present invention;

[0027] Figure 2 It is a schematic diagram of a groove and a stress-bearing groove formed on the foam aluminum in one embodiment of the present invention;

[0028] Figure 3 It is a schematic diagram of placing a force-bearing part and an expansion adhesive member on the foam aluminum in one embodiment of the present invention;

[0029] Figure 4 A schematic diagram of placing foam aluminum in a mold cavity structure in one embodiment of the present invention;

[0030] Figure 5 A schematic diagram of a via hole and a hot melt self-tapping screw in one embodiment of the present invention;

[0031] Figure 6 It is a schematic diagram of fixing foam aluminum in a cavity structure in one embodiment of the present invention;

[0032] Figure 7 This is a specific flow chart of step S2 in one embodiment of the present invention;

[0033] Figure 8 This is a specific flow chart of step S3 in one embodiment of the present invention;

[0034] Fig. 9 This is a flow chart of fixing foam aluminum in a cavity structure in one embodiment of the present invention.

[0035] Component number description

[0036] 1. Foam aluminum; 2. Groove; 3. Stress-bearing part; 4. Expansion adhesive; 5. Cavity structure; 6. Hot-melt self-tapping screws; 7. Stress-bearing part groove; 8. Via hole. DETAILED DESCRIPTION

[0037] The following is an explanation of the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the features in the following embodiments and the embodiments can be combined with each other without conflict. It should also be understood that the terms used in the embodiments of the present invention are intended to describe specific embodiments, rather than to limit the scope of protection of the present invention. The test methods for which specific conditions are not specified in the following examples are usually carried out under conventional conditions or according to the conditions recommended by the manufacturers.

[0038] When numerical ranges are given in the embodiments, it should be understood that, unless otherwise specified in the present invention, both endpoints of each numerical range and any value between the two endpoints can be selected. Unless otherwise defined, all technical and scientific terms used in the present invention are familiar to those skilled in the art and the description of the present invention, and any methods, equipment and materials of the prior art similar or equivalent to the methods, equipment and materials described in the embodiments of the present invention can also be used to implement the present invention.

[0039] It should be noted that the terms such as "upper", "lower", "left", "right", "middle" and "one" etc. used in this specification are only for the convenience of description and are not intended to limit the scope of implementation of the present invention. Changes or adjustments to their relative relationships, without substantially changing the technical content, should also be regarded as the scope of implementation of the present invention.

[0040] See also Figures 1 to 8 A processing method of foam aluminum 1 and a vehicle body cavity structure using the processing method, in which a groove 2 is opened on the foam aluminum 1, a force-bearing part 3 is embedded, an expansion adhesive 4 is pasted in the groove 2, the foam aluminum 1 is bonded and fixed to the cavity structure 5 by the expansion adhesive 4, and the foam aluminum 1 is fixed to the cavity structure 5 by providing a force point by the force-bearing part 3. The technical problem of poor fixing effect of the foam aluminum 1 in the cavity structure 5 in the prior art is improved. The processing method enables the foam aluminum 1 to be stably fixed and connected to the cavity structure 5, ensures that the filled cavity structure 5 generates a reaction force when subjected to bending and extrusion forces, and has a deformation buffer area.

[0041] See also Figure 1 The processing method of the foam aluminum 1 includes steps S1 to S3, which are described in detail as follows:

[0042] Step S1, forming a groove 2 on the surface of the foam aluminum 1.

[0043] In one embodiment of the present invention, the shape of the foam aluminum 1 matches the cavity structure 5 to be filled, so that the foam aluminum 1 can be placed in the cavity structure 5 to be filled. The molding shape of the foam aluminum 1 is not easy to control, and the foam aluminum 1 is processed into a suitable shape and size according to the shape of the internal cavity of the cavity structure 5 to be filled after molding.

[0044] See also Figure 2 and Figure 3 In one embodiment of the present invention, after the shape and size of the foam aluminum 1 are processed, a groove process is performed on the surface of the foam aluminum 1 along the direction toward the inside of the foam aluminum 1 to open a plurality of grooves 2. The shape of the groove 2 includes but is not limited to a cuboid, a cylinder, etc., and the number of the groove 2 is at least one. The groove 2 opened on the surface of the foam aluminum 1 is located on the surface where the foam aluminum 1 and the cavity structure 5 are in contact, so that the expansion adhesive 4 can fill the gap between the foam aluminum 1 and the cavity structure 5 after being heated and expanded, and the foam aluminum 1 and the cavity structure 5 are bonded and fixed together.

[0045] See also Figure 2 , Figure 3 and Figure 6 In one embodiment of the present invention, the number of grooves 2 opened on the surface of the foam aluminum 1 is several, and the grooves 2 are opened on at least two opposite surfaces of the foam aluminum 1, so that there are grooves 2 on several surfaces of the foam aluminum 1 and the cavity structure 5 that are opposite and adjacent, so that after the expansion adhesive 4 is expanded by heat, at least two groups of adjacent and opposite surfaces of the foam aluminum 1 and the cavity structure 5 can be bonded together, so that the bonding between the foam aluminum 1 and the cavity structure 5 is more firm, and the relative extrusion force of the expansion adhesive 4 on the foam aluminum 1 is dispersed in several directions, so that the force of the foam aluminum 1 in the cavity structure 5 is more uniform. In one embodiment, the grooves 2 opened on the surface of the foam aluminum 1 are located on two opposite surfaces, and the directions of the extrusion force of the expansion adhesive 4 on the foam aluminum 1 are two opposite directions, so that the force of the foam aluminum 1 in the cavity structure 5 is uniform, which is conducive to the fixed bonding of the foam aluminum 1 in the cavity structure 5. In other embodiments, the grooves 2 can also be opened on two adjacent surfaces of the foam aluminum 1.

[0046] Step S2, embedding a plurality of force-bearing parts 3 into the foam aluminum 1.

[0047] In one embodiment of the present invention, the force-bearing part 3 is embedded in the foam aluminum 1 to provide a force point for the foam aluminum 1, so that the foam aluminum 1 can be mechanically connected to the cavity structure 5, and the firmness of the foam aluminum 1 and the cavity structure 5 is enhanced. The material of the force-bearing part 3 does not react with the foam aluminum 1, and can withstand the tensile force that fixes the foam aluminum 1 and the cavity structure 5. The shape, size and thickness of the force-bearing part 3 match the foam aluminum 1, so that a plurality of force-bearing parts 3 can be embedded in the foam aluminum 1.

[0048] See also Figure 7 In step S2, embedding a plurality of force-bearing parts 3 into the foam aluminum 1 includes step S21 and step S22, which are described in detail as follows:

[0049] Step S21, a plurality of force-bearing grooves 7 are formed on the foam aluminum 1;

[0050] Step S22, embedding the force-bearing part 3 into the foam aluminum 1 through the force-bearing part groove 7.

[0051] See also Figure 2 , Figure 3 and Figure 6 In one embodiment of the present invention, a plurality of force-bearing parts 3 are embedded in the foam aluminum 1. A plurality of force-bearing part grooves 7 are provided on the foam aluminum 1, and the force-bearing part grooves 7 match the force-bearing part 3. The force-bearing part 3 can be fixed in the force-bearing part grooves 7, and the force-bearing part 3 is embedded in the foam aluminum 1 through the force-bearing part grooves 7. A plurality of force-bearing part grooves 7 are provided on the foam aluminum 1, so that a plurality of force-bearing parts 3 can be embedded in the foam aluminum 1. The plurality of force-bearing parts 3 in the foam aluminum 1 can provide a plurality of force-bearing points for the foam aluminum 1, so that the foam aluminum 1 can form a plurality of fixed points with the cavity structure 5 through the plurality of force-bearing points. Since the positions and angles of the force-bearing parts 3 embedded in the foam aluminum 1 are different, the positions and angles of the force-bearing points formed by the force-bearing parts 3 in the foam aluminum 1 are also different, so that the force positions and directions of the plurality of fixed points are different after the foam aluminum 1 and the cavity structure 5 are connected, so that the foam aluminum 1 and the cavity structure 5 are fixed more firmly.

[0052] Step S3 , placing the expansion adhesive 4 in the groove 2 , and bonding the foam aluminum 1 to the cavity structure 5 to be filled through the expansion adhesive 4 .

[0053] See also Figure 8 , step S3 includes steps S31 to S33, which are described in detail as follows;

[0054] Step S31, placing the expansion adhesive 4 in the groove 2;

[0055] Step S32, placing the foam aluminum 1 with the expansion adhesive 4 placed thereon into the cavity structure 5 to be filled;

[0056] Step S33 , heating the foam aluminum 1 and the cavity structure 5 to a preset temperature to expand the expansion adhesive 4 and bond the foam aluminum 1 and the cavity structure 5 .

[0057] See also Figure 3 , Figure 4 and Figure 6In one embodiment of the present invention, an expansion adhesive 4 is placed in each groove 2 opened on the foam aluminum 1. The shape of the expansion adhesive 4 is not particularly limited and may be spherical, cubic, etc. After the expansion adhesive 4 is placed in all the grooves 2 of the foam aluminum 1, the foam aluminum 1 with the expansion adhesive 4 is placed in a preset position in the cavity structure 5 to be filled, and the foam aluminum 1 and the cavity structure 5 are heated to a preset temperature. The expansion adhesive 4 expands when the temperature exceeds the preset temperature. After the expansion adhesive 4 expands, the foam aluminum 1 and the cavity structure 5 are bonded and fixed together.

[0058] In one embodiment of the present invention, the processing method further includes fixing the cavity structure 5 to the force-bearing part 3 to strengthen the firmness between the foam aluminum 1 and the cavity structure 5. The fixing connection method between the cavity structure 5 and the force-bearing part 3 includes but is not limited to bolt fixing, riveting fixing, clamping fixing and other fixing connection methods.

[0059] In one example of the present invention, a vehicle body cavity structure is also provided, and the vehicle body cavity structure uses the processing method of the foam aluminum 1 described in any one of the above. In the vehicle body cavity structure, for example, any cavity structure 5 or any number of cavity structures 5 such as the front and rear anti-collision beams, A-pillars, B-pillars, C-pillars, door sill beams, seat cross beams, top cross beams, energy absorption boxes, etc. use the processing method of the foam aluminum 1, so that the vehicle body cavity structure and the foam aluminum 1 filled inside are more firmly fixed, the foam aluminum 1 does not move in the vehicle body cavity structure, and the vehicle body cavity structure has better anti-collision performance, for example: when the vehicle body cavity structure is subjected to bending and extrusion forces in two directions, a reaction force is generated, and the vehicle body cavity structure has a deformed buffer area to absorb impact energy, etc.

[0060] See also Figure 5 and Figure 6 In one embodiment of the present invention, the force-bearing part 3 and the cavity structure 5 are fixed by hot-melt self-tapping screws 6. A through hole 8 is opened on the cavity structure 5, and the position of the through hole 8 matches the position of the force-bearing part 3, so that the hot-melt self-tapping screw 6 can pass through the through hole 8 and be fixedly connected to the force-bearing part 3. The hot-melt self-tapping screw 6 also passes through the foam aluminum 1. After the hot-melt self-tapping screw 6 passes through the through hole 8, it taps the force-bearing part 3 at a certain speed and pressure and penetrates the force-bearing part 3 to achieve a threaded connection with the force-bearing part 3, so that the force-bearing part 3 and the cavity structure 5 are fixedly connected, thereby achieving the fixed connection of the foam aluminum 1 to the cavity structure 5 with high firmness. In one embodiment, an aluminum plate is used as the force-bearing part 3 to facilitate the hot-melt self-tapping screw 6 to penetrate the aluminum plate to achieve a threaded fixed connection.

[0061] See also Figures 2 to 6 as well as Fig. 9In one embodiment of the present invention, the foam aluminum 1 is processed into a shape and size that matches the cavity structure 5 with the cavity structure 5 to be filled as a standard. In this embodiment, the expansion adhesive 4 is a structural adhesive, the force-bearing part 3 is an aluminum plate, and the force-bearing part groove 7 is an aluminum plate groove. Several grooves 2 are opened on the surface of the foam aluminum 1. Specifically, at least one groove 2 is opened on several surfaces of the foam aluminum 1 that are adjacent to and opposite to the cavity structure 5. The shape of the groove 2 is a rectangular parallelepiped, and an expandable and sticky structural adhesive is arranged in each groove 2. Several aluminum plate grooves are opened on the foam aluminum 1, and at least one aluminum plate groove is opened on several surfaces of the foam aluminum 1, and an aluminum plate is embedded in each aluminum plate groove. A via hole 8 is drilled at the position where the cavity structure 5 matches the aluminum plate, and at least one via hole 8 is opened on each aluminum plate, and the foam aluminum 1 is placed in the cavity structure 5. The FDS process is used to use hot-melt self-tapping screws 6 to pass through the vias 8 to perform tapping and perforation on the aluminum plate. Under the rotation speed and pressure of the hot-melt self-tapping screws 6, the aluminum plate is drilled with threaded holes, and the hot-melt self-tapping screws 6 are screwed and fixed on the aluminum plate. Each via 8 is fixed on the aluminum plate through a hot-melt self-tapping screw 6 through the via 8, so that the foam aluminum 1 is fixed in the cavity structure 5. When the filled cavity structure 5 is electrophoretically baked, the structural adhesive expands due to heat to fill the gap between the foam aluminum 1 and the cavity structure 5, and the foam aluminum 1 and the cavity structure 5 are bonded and fixed together. The foam aluminum 1 and the cavity structure 5 are fixed simultaneously by gluing and mechanical fixing, which improves the firmness of the fixation between the foam aluminum 1 and the cavity structure 5, and allows the foam aluminum 1 and the expanded structural adhesive to fill the cavity structure 5, so that the filled cavity structure 5 generates a reaction force when subjected to bending and extrusion forces in two directions, and has a deformation buffer area.

[0062] The present invention provides a processing method of foam aluminum 1 and a body cavity structure using the processing method. The foam aluminum 1 is firmly fixed in the cavity structure 5 and / or the body cavity structure by adhesive fixation and mechanical fixation by hot melt self-tapping screws 6. The operation is simple and convenient and can be applied to a variety of cavity structures 5 and / or body cavity structures. Therefore, the present invention effectively overcomes some practical problems in the prior art and has high utilization value and use significance.

[0063] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by a person of ordinary skill in the art without departing from the spirit and technical concept disclosed by the present invention shall still be covered by the claims of the present invention.

Claims

1. A method for processing foamed aluminum, characterized in that: The steps include: Providing a groove on the surface of the foam aluminum; Embedding a plurality of force-bearing parts into the foamed aluminum; An expansion adhesive is placed in the groove, and the foam aluminum is bonded to the cavity structure to be filled by the expansion adhesive.

2. The method for processing foamed aluminum according to claim 1, characterized in that: The groove is formed on the surface where the foam aluminum contacts the cavity structure.

3. The method for processing foamed aluminum according to claim 1, characterized in that: The number of the grooves is several, and the grooves are at least formed on two opposite surfaces of the foam aluminum.

4. The method for processing foamed aluminum according to claim 1, characterized in that: The step of embedding a plurality of force-bearing parts into the foam aluminum comprises: A plurality of force-bearing grooves are provided on the foam aluminum; The force-bearing part is embedded into the foam aluminum through the force-bearing part groove.

5. The method for processing foamed aluminum according to claim 1, characterized in that: The processing method also includes: fixedly connecting the force-bearing part to the cavity structure to enhance the firmness between the foam aluminum and the cavity structure.

6. The method for processing foamed aluminum according to claim 1, characterized in that: The step of placing the expansion adhesive in the groove and bonding the foam aluminum to the cavity structure to be filled by the expansion adhesive comprises: placing the expansion adhesive member in the groove; The foam aluminum with the expansion adhesive placed thereon is placed into the cavity structure to be filled; the foam aluminum and the cavity structure are heated to a preset temperature to expand the expansion adhesive and bond the foam aluminum and the cavity structure.

7. The method for processing foamed aluminum according to claim 1, characterized in that: The area size and thickness of the force-bearing part match the area and thickness of the foam aluminum.

8. A vehicle body cavity structure, characterized in that: The vehicle body cavity structure comprises: a cavity structure and foamed aluminum, wherein the foamed aluminum is filled into the cavity structure; wherein the foamed aluminum is processed by the processing method described in any one of claims 1 to 7 above.

9. The vehicle body cavity structure according to claim 8, characterized in that: The cavity structure and the force-bearing part are fixed by hot-melt self-tapping screws.

10. The vehicle body cavity structure according to claim 9, characterized in that: The cavity structure is provided with a through hole matching the position of the force-bearing part; the hot-melt self-tapping screws fix the force-bearing part, the foam aluminum and the cavity structure through the through hole.

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