H arm forming method and H arm assembly structure

Abstract

The invention relates to an H-shaped arm forming method and an H-shaped arm assembly structure, and belongs to the technical field of vehicle suspensions.The H-shaped arm forming method comprises the steps that an H-shaped closed framework is made of a plate-shaped continuous fiber reinforced thermoplastic composite material, and the H-shaped closed framework is placed in an H-shaped arm injection mold; integrally performing injection molding on a fiber-reinforced thermoplastic composite material in the H-shaped arm injection mold, and forming a reinforcing body formed by the fiber-reinforced thermoplastic composite material on the H-shaped closed framework. According to the H arm forming method and the H arm assembly structure, the mechanical strength performance of all parts keeps high integrity, and meanwhile the weight can be greatly reduced.

Description

Technical Field

[0001] The present application relates to the technical field of vehicle suspension, and in particular to an H-arm forming method and an H-arm assembly structure. Background Art

[0002] The H-arm in the automobile suspension system, also known as the H-arm multi-link suspension, is an advanced suspension design. It has strong structural rigidity, especially lateral rigidity, which plays an absolute guiding role in the transmission of lateral force, thereby improving the vehicle's handling. At the same time, since the H-arm has no trailing arm structure and does not occupy the chassis space for layout, it is conducive to the battery layout of new energy vehicles. At present, it has gradually become the mainstream configuration of new cars, new platforms, and new energy vehicles.

[0003] At present, most H-arms are made of cast or stamped metal parts. Although their mechanical strength can meet the performance requirements of vehicle suspension, their heavy weight has a great impact on the overall performance of the suspension. In addition, in the prior art, the molding process of the H-arm requires the steps of casting and welding the upper and lower pieces, which results in a complex production process and high production cost.

[0004] Therefore, proposing an H-arm forming method and an H-arm assembly structure with both lightweight and high integration degree has great significance in the automotive field. Summary of the invention

[0005] In view of the deficiencies in the prior art, the present application provides an H-arm forming method and an H-arm assembly structure, aiming to provide an H-arm that is both lightweight and highly integrated.

[0006] To achieve the above objectives, the present application provides an H-arm forming method, comprising: An H-shaped closed frame is made of a plate-shaped continuous fiber reinforced thermoplastic composite material, and the H-shaped closed frame is placed in an H-arm injection mold; The fiber-reinforced thermoplastic composite material is integrally injection-molded in the H-arm injection mold to form a reinforcement body composed of the fiber-reinforced thermoplastic composite material on the H-shaped closed frame.

[0007] Optionally, the H-shaped closed frame is made of plate-shaped continuous fiber reinforced thermoplastic composite material, comprising: The plate-like continuous fiber reinforced thermoplastic composite material is cut into planar preforms, the planar preforms are heated and softened, so that each layer of the plate-like continuous fiber material is fully infiltrated and fused, and then the heated planar preforms are pushed toward the center to form an H-shaped closed skeleton.

[0008] Optionally, before the step of integrally injecting the fiber-reinforced thermoplastic composite material into the H-arm injection mold, the method further comprises: The metal parts are embedded in the H-arm injection mold; the metal parts include: a bushing and a ball stud.

[0009] Optionally, the reinforcing body has reinforcing ribs, and the reinforcing body and the reinforcing ribs are integrally injection molded.

[0010] Optionally, the plate-shaped continuous fiber reinforced thermoplastic composite material and the fiber reinforced thermoplastic composite material use the same resin matrix material; the resin matrix material is a thermoplastic resin.

[0011] Optionally, the fiber content of the plate-shaped continuous fiber reinforced thermoplastic composite material and the fiber content of the fiber reinforced thermoplastic composite material are both 30 wt % to 70 wt %.

[0012] Optionally, the fiber-reinforced thermoplastic composite reinforcement uses short fibers or long fibers.

[0013] In addition, to achieve the above-mentioned purpose, the present application further provides an H-arm assembly structure, comprising: a subframe connecting portion and a steering knuckle mounting portion; wherein the first connecting end of the subframe connecting portion has a bushing and a ball stud, and the mounting end of the steering knuckle mounting portion has a bushing and a ball stud, and the H-arm molding method as described above is applied, and the H-arm assembly structure comprises: A plate-shaped continuous fiber reinforced thermoplastic composite H-shaped closed skeleton, a fiber reinforced thermoplastic composite reinforcement formed by injection molding, and metal parts embedded before injection molding, wherein the metal parts are bushings and ball studs.

[0014] Optionally, the reinforcement body has reinforcement ribs.

[0015] Optionally, the reinforcing ribs are provided with diversion holes, and the accumulated water and sediment can be diverted along the reinforcing ribs and flow out of the H-arm through the diversion holes.

[0016] The present application provides an H-arm forming method and an H-arm assembly structure, the method comprising: making an H-shaped closed frame with a plate-shaped continuous fiber reinforced thermoplastic composite material, and placing the H-shaped closed frame in an H-arm injection mold; integrally injecting the fiber reinforced thermoplastic composite material in the H-arm injection mold to form a reinforcement body composed of the fiber reinforced thermoplastic composite material on the H-shaped closed frame.

[0017] Since the continuous fiber reinforced thermoplastic composite material used to make the H-shaped closed frame and the fiber reinforced thermoplastic composite material used for injection molding use the same matrix resin and have similar fiber content, the material fusion degree of the entire H-arm is very high, thereby enhancing the mechanical properties of the entire H-arm assembly structure.

[0018] Compared with the existing metal H-arm formed by welding the upper and lower pieces after casting, the H-arm assembly structure formed by integral injection molding of fiber-reinforced composite materials in this application maintains a high degree of mechanical strength and integrity, while the weight can be greatly reduced. It can also avoid a series of processes such as removing the sand core when manufacturing the metal H-arm, thereby improving production efficiency and reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of an H-shaped closed frame forming method and an H-arm assembly structure of an embodiment of the present application; Figure 2 A schematic diagram of an H-arm assembly structure of an H-arm forming method and an H-arm assembly structure according to an embodiment of the present application; Figure 3 This is a right view of an H-arm assembly structure of an embodiment of an H-arm forming method and an H-arm assembly structure of the present application; Figure 4 This is a bottom view of an H-arm assembly structure of an embodiment of an H-arm forming method and an H-arm assembly structure of the present application.

[0020] Reference numerals: H-arm assembly structure 1, metal parts 2, bushing 21, ball pin 22, subframe connecting part 3, steering knuckle mounting part 4, stabilizer bar mounting bracket 5, shock absorber spring mounting seat 6, conical circular protrusion 7, reinforcement body 8, reinforcement rib 9, H-shaped closed frame 10. DETAILED DESCRIPTION

[0021] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0022] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0023] The widely used metal H-arm forming process has the steps of casting the upper and lower pieces separately and then welding them, which is relatively complicated. Although the mechanical strength of the metal H-arm can meet the performance requirements of the vehicle suspension, its large weight has a great impact on the overall performance of the suspension.

[0024] In an embodiment of an H-arm forming method and an H-arm assembly structure of the present application, an H-arm forming method is provided, comprising: making an H-shaped closed skeleton 10 with a plate-shaped continuous fiber reinforced thermoplastic composite material, and placing the H-shaped closed skeleton 10 in an H-arm injection mold; integrally injecting the fiber reinforced thermoplastic composite material in the H-arm injection mold to form a reinforcement body 8 composed of the fiber reinforced thermoplastic composite material on the H-shaped closed skeleton 10.

[0025] It should be noted that, refer to Figures 1 to 4 The plate-shaped continuous fiber reinforced thermoplastic composite material is heated and softened to form an H-shaped closed frame 10, and the H-shaped closed frame 10 is placed in an H-arm injection mold, and then the metal parts 2 are embedded. The fiber reinforced thermoplastic composite material is integrally injection molded in the H-arm injection mold. The fiber reinforced thermoplastic composite material and the plate-shaped continuous fiber reinforced thermoplastic composite material use the same matrix resin and have similar fiber content.

[0026] Specifically, the plate-shaped continuous fiber reinforced thermoplastic composite material is first heated and softened, and then placed in the injection mold 11, and the fiber reinforced thermoplastic composite material is injected into the H-shaped closed frame 10 by high-pressure injection molding, and the injection mold is controlled at a relatively high temperature and pressure, so that the H-shaped closed frame 10 and the fiber reinforced thermoplastic composite reinforcement 8 to be injected are fused to form the H-arm body. Before the above-mentioned one-piece injection molding step, the metal part 2 will be pre-embedded in the H-arm injection mold, and the metal part 2 and the H-arm body are obtained by one-piece injection molding to obtain the H-arm assembly structure 1.

[0027] In the above implementation process, the H-shaped closed skeleton 10 uses a plate-shaped continuous fiber reinforced thermoplastic composite material, which is convenient for pushing and pressing in the injection mold after being heated to form the H-shaped closed skeleton 10. The size of the plate-shaped continuous fiber reinforced thermoplastic composite material can be changed at any time within a reasonable range according to actual needs, and then the above-mentioned integrated injection molding step is performed, and the size of the plate-shaped continuous fiber reinforced thermoplastic composite material can be adjusted according to the required shape and performance of the H arm.

[0028] Since the molded H-arm composite material matrix is ​​the same thermoplastic resin material, there are no mechanical or other material connectors between the H-shaped closed frame 10 and the fiber-reinforced thermoplastic composite material filled during integral injection molding, thereby ensuring the consistency of the mechanical properties of the entire H-arm body and the H-arm assembly structure 1.

[0029] In this embodiment, compared with the currently common metal H-arm formed by welding the upper and lower pieces after casting, the H-arm assembly structure 1 formed by integral injection molding of the fiber-reinforced composite material maintains a high degree of mechanical strength and integrity of each part, while the weight can be greatly reduced. It can also avoid a series of processes such as removing the sand core when making the metal H-arm, thereby improving production efficiency and reducing production costs.

[0030] Furthermore, the H-shaped closed skeleton 10 is made of the plate-like continuous fiber reinforced thermoplastic composite material, which specifically includes: cutting the plate-like continuous fiber reinforced thermoplastic composite material into planar preforms, heating and softening the planar preforms so that the layers of the plate-like continuous fiber material are fully infiltrated and fused, and then pushing the heated planar preforms toward the center to form the H-shaped closed skeleton 10.

[0031] In this embodiment, an H-shaped closed frame 10 composed of a plate-shaped continuous fiber reinforced thermoplastic composite material is used as the main load-bearing structure, and the load applied to the H-arm is transmitted to the H-shaped closed frame 10 through the fiber reinforced thermoplastic composite reinforcement 8. The H-shaped closed frame 10 supports and strengthens the entire H-arm, thereby improving the mechanical strength of the entire H-arm and the integrity of the mechanical properties.

[0032] Furthermore, before the step of integrally injecting the fiber-reinforced thermoplastic composite material into the H-arm injection mold, the method further comprises: pre-embedding a metal part 2 in the H-arm injection mold; the metal part 2 comprises: a bushing 21 and a ball stud 22 .

[0033] It should be noted that, refer to Figure 1 and Figure 2 The H-arm assembly structure 1 and the molding method thereof involved in this embodiment eliminate the connection structure between the traditional metal H-arm and the bushing 21 and the ball stud 22. The bushing 21 and the ball stud 22 can be directly placed in the corresponding positions of the injection mold in advance and assembled into the subframe connection part 3 and the steering knuckle mounting part 4 designed for the H-arm body through one-piece injection molding.

[0034] In this embodiment, the method of pre-embedding the metal parts 2 before injection molding is adopted, and there is no need to consider the durability and additional assembly process caused by the difference in material properties between the composite material and the metal.

[0035] Furthermore, the reinforcing body 8 has reinforcing ribs 9, and the reinforcing body 8 and the reinforcing ribs 9 are integrally injection molded. The reinforcing ribs 9 enhance the structural strength of the H-arm body.

[0036] Furthermore, the plate-shaped continuous fiber reinforced thermoplastic composite material and the fiber reinforced thermoplastic composite material adopt the same resin matrix material; the resin matrix material is a thermoplastic resin.

[0037] It should be noted that the resin matrix material is a thermoplastic resin, specifically PA, PP, PEEK and the like.

[0038] In this embodiment, since the molded composite material matrix is ​​the same thermoplastic resin material, there are no mechanical or other material connectors between the H-shaped closed frame 10 and the fiber-reinforced thermoplastic composite material filled during integral injection molding, thereby ensuring the consistency of the mechanical properties of the entire H-arm body and the H-arm assembly structure 1.

[0039] Furthermore, the fiber content of the plate-shaped continuous fiber reinforced thermoplastic composite material and the fiber content of the fiber reinforced thermoplastic composite material are both 30wt% to 70wt%.

[0040] In this embodiment, since the fiber contents of the H-shaped closed frame 10 and the fiber-reinforced thermoplastic composite material used for injection molding are similar, the material fusion degree of the entire H-arm is very high, which can enhance the mechanical properties of the entire H-arm assembly structure 1.

[0041] Furthermore, the fiber-reinforced thermoplastic composite reinforcement 8 uses short fibers or long fibers.

[0042] In this embodiment, the main load-bearing skeleton adopts continuous fiber reinforced thermoplastic composite material, and the reinforcement body 8 and the reinforcing ribs 9 adopt short fiber or long fiber reinforced thermoplastic composite material for connection and reinforcement. The process molding cycle is short, the adjustable space is ample, and fully automated production is easy to achieve.

[0043] In addition, the embodiment of the present application also proposes an H-arm assembly structure 1, comprising: a subframe connecting portion 3, and a steering knuckle mounting portion 4; wherein the first connecting end of the subframe connecting portion 3 has a bushing 21 and a ball stud 22, and the mounting end of the steering knuckle mounting portion 4 has a bushing 21 and a ball stud 22, and the H-arm molding method as described above is applied, and the H-arm assembly structure 1 includes: a plate-like continuous fiber reinforced thermoplastic composite H-shaped closed skeleton 10, a fiber reinforced thermoplastic composite reinforcement 8 formed by injection molding, and a metal part 2 embedded before injection molding, wherein the metal part 2 is a bushing 21 and a ball stud 22.

[0044] It should be noted that, refer to Figure 2 The subframe connection part 3 has two connection ends, which are connected to the automobile subframe through bushings 21 and ball pins 22 respectively; the steering knuckle mounting part 4 has two connection ends, the front connection end is connected to the steering knuckle through bushings 21 and ball pins 22, and the rear connection end is connected to the steering knuckle through stabilizer bar mounting bracket 5. The front side of the H arm is Figure 2 Above, the back of the H arm is Figure 2 Below.

[0045] In this embodiment, the H-shaped closed frame 10 and the reinforcement body 8 use the same matrix resin and have similar fiber content, and the material fusion degree is very high, which can enhance the mechanical properties of the entire H-arm assembly structure 1. Compared with the traditional metal H-arm, the weight can be greatly reduced, the manufacturing process is simplified, the production efficiency is improved, and the production cost is reduced.

[0046] For example, refer to Figures 2 to 4 The H-arm assembly structure 1 specifically includes an H-arm body, which is provided with a subframe connection portion 3 and a steering knuckle mounting portion 4, and the subframe connection portion 3 and the steering knuckle mounting portion 4 are both installed with a metal part 2 composed of a bushing 21 and a ball stud 22. When designing the H-arm injection mold, a stabilizer bar mounting bracket 5 is also provided, and the stabilizer bar mounting bracket 5 is fastened to the ball stud 22 on the vehicle stabilizer bar through a nut; a shock-absorbing spring mounting seat 6 and a conical circular protrusion 7 are also provided to limit the installation position of the shock-absorbing spring and ensure that the shock-absorbing spring is in the designed position. The H-arm body includes a fiber-reinforced thermoplastic composite reinforcement 8, a fiber-reinforced thermoplastic composite reinforcement rib 9 and a continuous fiber-reinforced thermoplastic composite H-type closed skeleton 10.

[0047] Furthermore, the reinforcement body 8 has reinforcement ribs 9 .

[0048] In this embodiment, through the design of the injection mold, the reinforcing ribs 9 can be set in the fiber reinforced thermoplastic composite reinforcement 8 according to the stress conditions of the H-arm assembly structure 1 in actual working conditions and the application needs during actual loading, so as to provide reasonable stress conduction and dispersion performance, thereby improving the mechanical properties such as torsional stiffness of the H-arm assembly structure 1. The reinforcing ribs are designed based on the actual multi-objective performance requirements through the topological optimization model. The removal and retention of the units in the design space are determined according to the algorithm, and the distribution and structure of the reinforcing ribs are optimized. The retained units constitute the final topological solution, which reduces the weight of the H-arm assembly structure under the premise of limited position and ensuring structural strength and stiffness.

[0049] Furthermore, the reinforcing rib 9 is provided with a diversion hole, and the accumulated water and sediment can be diverted along the reinforcing rib and flow out of the H arm through the diversion hole.

[0050] It should be noted that, refer to Figure 3The H-arm assembly structure 1 is in an arc shape with a high rear end and a low front end. While providing a way to avoid the transmission shaft and improve rigidity, the characteristics of the one-piece injection molding process are used to design a diversion structure for water or sediment that is prone to occur in actual working conditions. When the reinforcing rib 9 is set above the H-arm, the reinforcing rib 9 can be used as a diversion structure. According to the structural characteristics of the H-arm assembly structure 1 with a high rear end and a low front end, water holes are appropriately set on the reinforcing rib 9 to facilitate the passage of water and sediment through the reinforcing rib 9. At the same time, a diversion groove can be set on the plate-shaped reinforcement body 8, so that the accumulated water and sediment can flow from high to low to the lowest point on the top surface of the H-arm under the diversion effect of the reinforcing rib 9 and the groove. A water hole is also set at the lowest point on the top surface of the H-arm to facilitate the flow of water and sediment out of the H-arm.

[0051] In this embodiment, the reinforcing ribs 9 can divert the accumulated water and silt. Without affecting the service life of the H-arm, the reinforcing ribs 9 are used to divert the water and the water holes are appropriately set according to the actual arrangement of the reinforcing ribs 9, so as to take into account both the lightweight and mechanical properties of the H-arm.

[0052] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0053] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for forming an H-arm, characterized in that: include: An H-shaped closed frame is made of a plate-shaped continuous fiber reinforced thermoplastic composite material, and the H-shaped closed frame is placed in an H-arm injection mold; The fiber-reinforced thermoplastic composite material is integrally injection-molded in the H-arm injection mold to form a reinforcement body composed of the fiber-reinforced thermoplastic composite material on the H-shaped closed frame.

2. The H-arm forming method according to claim 1, characterized in that: The H-shaped closed frame is made of plate-shaped continuous fiber reinforced thermoplastic composite material, comprising: The plate-like continuous fiber reinforced thermoplastic composite material is cut into planar preforms, the planar preforms are heated and softened, so that each layer of the plate-like continuous fiber material is fully infiltrated and fused, and then the heated planar preforms are pushed toward the center to form an H-shaped closed skeleton.

3. The H-arm forming method according to claim 1, characterized in that: Before the step of integrally injecting the fiber-reinforced thermoplastic composite material into the H-arm injection mold, the method further comprises: The metal parts are embedded in the H-arm injection mold; the metal parts include: a bushing and a ball stud.

4. The H-arm forming method according to claim 1, characterized in that: The reinforcing body is provided with reinforcing ribs, and the reinforcing body and the reinforcing ribs are integrally injection-molded.

5. The method for forming an H-arm according to any one of claims 1 to 4, characterized in that: The plate-shaped continuous fiber reinforced thermoplastic composite material and the fiber reinforced thermoplastic composite material adopt the same resin matrix material; the resin matrix material is a thermoplastic resin.

6. The method for forming an H-arm according to any one of claims 1 to 4, characterized in that: The fiber content of the plate-shaped continuous fiber reinforced thermoplastic composite material and the fiber content of the fiber reinforced thermoplastic composite material are both 30 wt % to 70 wt %.

7. The method for forming an H-arm according to any one of claims 1 to 4, characterized in that: The fiber reinforced thermoplastic composite reinforcement adopts short fibers or long fibers.

8. An H-arm assembly structure, comprising: a subframe connecting portion, a steering knuckle mounting portion; wherein: The first connecting end of the sub-frame connecting part has a bushing and a ball stud, and the mounting end of the steering knuckle mounting part has a bushing and a ball stud, characterized in that the H-arm forming method according to any one of claims 1 to 7 is applied, and the H-arm assembly structure further includes: A plate-shaped continuous fiber reinforced thermoplastic composite H-shaped closed skeleton, a fiber reinforced thermoplastic composite reinforcement formed by injection molding, and metal parts embedded before injection molding, wherein the metal parts are bushings and ball studs.

9. The H-arm assembly structure according to claim 8, characterized in that: The reinforcement body is provided with reinforcement ribs.

10. The H-arm assembly structure according to claim 9, characterized in that: The reinforcing ribs are provided with guide holes, and the accumulated water and sediment can be guided along the reinforcing ribs and flow out of the H-arm through the guide holes.

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