Lightweight side pedal and manufacturing process thereof

Abstract

The invention discloses a light-weight side pedal. The light-weight side pedal comprises a pedal body, a protective cover, a pedal supporting seat and a fastening assembly. Through the newly designed process, compared with a traditional aluminum alloy pedal, the side pedal is simpler in structure, and the material cost is greatly reduced. Compared with a transmission aluminum alloy pedal, the novel process has the advantages that the manufacturing cost is lower, the manufacturing process and the manufacturing process are simpler, the price is excellent, various types of pedals can be produced, the overall assembly is simple, one-time forming can be realized during manufacturing, and manual multi-station process assembly is not needed. The light-weight side pedal solves the problems of vehicle oil consumption and the like, brings convenience to consumers, reduces the use cost of the consumers, and is light and fast to install, freely customized in style and environment-friendly.

Description

Technical Field:

[0001] The present invention relates to the technical field of automotive parts manufacturing, and particularly to a lightweight side pedal and its manufacturing process. Background Art:

[0002] Automobiles have become essential tools for family travel. Currently, in the domestic and foreign markets, medium and large-sized vehicles such as off-road vehicles, SUVs, and pickups are highly favored by consumers, and their sales are continuously increasing. Consumers also have higher functional requirements for such vehicles. As a common accessory for medium and large-sized vehicles, pedals are divided into two types: fixed and electric.

[0003] Currently, most pedals on the market are assembled by fixing plastic covers, aluminum alloy bodies, and die-castings with screws and nuts. Their materials are mainly aluminum alloy. Compared with the new lightweight pedals, they have problems such as high processing, raw material, and manufacturing costs, complex manufacturing processes, heavy products, increased vehicle weight and fuel consumption after installation. The replacement cost is high when damaged, and the styles are also single. Basically, only the original pedals provided by the vehicle factory can be replaced. Summary of the Invention:

[0004] The purpose of the present invention is to solve the existing problems and provide a lightweight side pedal and its manufacturing process.

[0005] The technical solution of the present invention is as follows:

[0006] A lightweight side pedal includes a pedal body, a protective cover, a pedal support seat, and a fastening component.

[0007] Preferably, the pedal support seat is installed on the pedal body through the fastening component.

[0008] Preferably, the pedal body further includes a main body substrate, a side covering layer, and a pedal anti-slip pad.

[0009] Preferably, the main body substrate is made from a formula with each component calculated by weight percentage, and the formula is 50%-70% polypropylene (PP), 20%-40% polyvinyl chloride (PVC), 5%-15% glass fiber, 3%-8% carbon fiber, 0.1%-0.5% antioxidant, 0.2%-0.8% lubricant, and 0.5%-3% colorant.

[0010] A manufacturing process of a lightweight side pedal, the manufacturing process includes the following steps:

[0011] S1. The formulated materials are mixed and heated, and the main body substrate is extruded by an extruder. The upper and lower unwinding machines unwind the CFRT sheet, that is, the continuous fiber reinforced thermoplastic composite sheet, synchronously;

[0012] S2. The co-extruder extrudes the raw materials of the outer anti-slip layer and the side covering layer;

[0013] S3. Mold forming: The main body substrate, CFRT sheet, outer anti-slip layer and side cladding layer are pressed into one through a mold.

[0014] S4. Through the sizing table, cool and shape the product.

[0015] S5. The tractor provides traction force to the product and pulls out the product.

[0016] S6. Fixed-length cutting: According to different requirements, use cutting equipment to customize different pedal lengths.

[0017] S7. Use the storage rack equipment for storage.

[0018] S8. The finished product is completed and awaits the next assembly process.

[0019] Preferably, the temperature of the front section of the barrel of the extruder is set between 200 - 230 °C, the temperature of the middle section of the barrel is 190 - 210 °C, the temperature of the rear section of the barrel is between 180 - 200 °C, the temperature of the die head is between 200 - 240 °C, the screw speed is 60 - 80 revolutions per minute, the extrusion pressure is between 20 - 30 MPa, and the traction speed is 0.5 - 1 meter per minute.

[0020] Preferably, the unwinding tension of the upper and lower unwinding machines is set between 100 - 200 N, the unwinding speed is about 0.8 - 1 meter per minute, and the winding speed is 0.7 - 0.9 meter per minute.

[0021] Preferably, the temperature of the sizing table is set between 30 - 40 °C, the temperature of the cooling medium is 10 - 25 °C, the vacuum degree is set between -0.08 MPa and -0.09 MPa, the sizing time is 30 - 50 seconds, and the sizing pressure is set between 0.3 - 0.5 MPa.

[0022] Preferably, the traction tension of the tractor is set between 200 - 300 N, the distance between the traction rollers is set between 50 - 100 mm, and the traction speed range: when the extrusion speed of the extruder is 0.5 - 1.5 meters per minute, the residence time on the sizing table is 30 - 55 seconds.

[0023] Preferably, the cutting wire speed of the cutting equipment is 10 - 30 mm / s, the feed speed is 0.3 - 0.5 mm / revolution, the rotational speed is set between 3000 - 5000 revolutions per minute, and the cutting edge angle of the tool is set to 40° - 60°.

[0024] The beneficial effects of the present invention are as follows:

[0025] 1. Through the newly designed process, compared with traditional aluminum alloy pedals, this side pedal has a simpler structure and greatly reduces the material cost.

[0026] 2. Compared with the production of traditional aluminum alloy pedals, the new process has lower manufacturing costs, simpler manufacturing processes, and excellent price-performance ratio. It can produce various types of pedals with simple overall assembly, and the manufacturing process can be formed in one step without manual multi-station assembly.

[0027] 3. The lightweight side pedals reduce problems such as vehicle fuel consumption, bringing convenience to consumers, reducing their usage costs, being easy and quick to install, having customizable styles, and being environmentally friendly. Description of the Drawings:

[0028] Figure 1 A three-dimensional schematic diagram of the side pedal of the present invention after removing one side cover;

[0029] Figure 2 A three-dimensional schematic diagram of the side pedal of the present invention;

[0030] Figure 3 A process flow chart of the present invention;

[0031] In the drawings: 1. Pedal main body; 2. Cover; 3. Pedal support seat; 4. Fastening assembly; 5. Main body substrate; 6. Side covering layer; 7. Outer anti-slip layer; 8. CFRT sheet. Detailed Embodiments:

[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0033] It should be noted that when a component is referred to as being "fixed to" another component, it can be directly on the other component or there may also be an intermediate component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intermediate component at the same time. When a component is considered to be "disposed on" another component, it can be directly disposed on the other component or there may be an intermediate component at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which the present invention belongs. The terms used in the description of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "or / and" used herein includes any and all combinations of one or more of the related listed items.

[0035] Example 1

[0036] As Figures 1 - 3 shown, a lightweight side step includes a step body 1, a protective cover 2, a step support base 3, and a fastening assembly 4.

[0037] Specifically, the step support base 3 is installed on the step body 1 through the fastening assembly 4.

[0038] Specifically, the step body 1 further includes a main body substrate 5, a CFRT sheet 8, a side coating layer 6, and an outer anti-slip layer 7.

[0039] Specifically, the main body substrate 5 is made of a formula with each component calculated by weight percentage. The formula is 50% polypropylene (PP), 20% polyvinyl chloride (PVC), 5% glass fiber, 3% carbon fiber, 0.1% antioxidant, 0.2% lubricant, and 0.5% colorant.

[0040] A manufacturing process for a lightweight side step, the manufacturing process includes the following steps:

[0041] S1. The formulated materials are mixed and heated, and the main body substrate 5 is extruded by an extruder. The upper and lower unwinding machines unwind the CFRT sheet 8, that is, the continuous fiber reinforced thermoplastic composite sheet, synchronously;

[0042] S2. The co-extruder extrudes the raw materials of the outer anti-slip layer 7 and the side coating layer 6;

[0043] S3. Mold forming, the main body substrate 5, the CFRT sheet 8, the outer anti-slip layer 7, and the side coating layer 6 are pressed into one body through a mold;

[0044] S4. Through a sizing table, cool and size the product;

[0045] S5. The tractor provides traction force for the product and pulls out the product;

[0046] S6. Fixed-length cutting: According to different requirements, use cutting equipment to customize different step lengths;

[0047] S7. Use a storage rack device for storage;

[0048] S8. The finished product is completed and waiting to enter the next assembly process.

[0049] Specifically, the front section temperature of the barrel of the extruder is set at 200 °C, the middle section temperature of the barrel is 190 °C, the rear section temperature of the barrel is between 180 °C and the head temperature is 200 °C, the screw speed is 60 revolutions per minute, the extrusion pressure is between 20 MPa, and the traction speed is 0.5 meters per minute.

[0050] Specifically, the unwinding tension of the upper and lower unwinding machines is set at 100 N, the unwinding speed is about 0.8 m / min, and the winding speed is 0.7 m / min.

[0051] Specifically, the temperature of the shaping table is set at 30 °C, the temperature of the cooling medium is 10 °C, the vacuum degree is set at -0.08 MPa, the shaping time is 30 seconds, and the shaping pressure is set at 0.3 MPa.

[0052] Specifically, the traction tension of the traction machine is set at 200 N, the distance between the traction rollers is set at 50 mm, and the traction speed range is as follows: when the extrusion speed of the extruder is 0.5 m / min, the residence time on the shaping table is 30 seconds.

[0053] Specifically, the cutting wire speed of the cutting equipment is 10 mm / s, the feed speed is 0.3 mm / rev, the rotation speed is set at 3000 rpm, and the cutting edge angle of the tool is set at 40°.

[0054] Example 2

[0055] As Figures 1 - 3 shown, a lightweight side step includes a step body 1, a cover 2, a step support base 3, and a fastening assembly 4.

[0056] Specifically, the step support base 3 is installed on the step body 1 through the fastening assembly 4.

[0057] Specifically, the step body 1 further includes a main body substrate 5, a CFRT sheet 8, a side coating layer 6, and a step anti-slip pad 7.

[0058] Specifically, the main body substrate 5 is made from a formula with each component calculated by weight percentage, and the formula is 64% polypropylene (PP), 29% polyvinyl chloride (PVC), 8% glass fiber, 6% carbon fiber, 0.4% antioxidant, 0.6% lubricant, and 2.1% colorant.

[0059] A manufacturing process for a lightweight side step, the manufacturing process includes the following steps:

[0060] S1. The formulated materials are mixed and heated and extruded into the main body substrate 5 by an extruder, and the upper and lower unwinding machines unwind the CFRT sheet 8, i.e., the continuous fiber reinforced thermoplastic composite sheet, synchronously;

[0061] S2. The co-extruder extrudes the raw materials of the outer anti-slip layer 7 and the side coating layer 6;

[0062] S3. Mold forming, through the mold, the main body substrate 5, the CFRT sheet 8, the outer anti-slip layer, and the side coating layer 6 are pressed into one body;

[0063] S4. Through the shaping table, the product is cooled and shaped;

[0064] S5. The tractor provides traction force to the product and pulls out the product;

[0065] S6. Fixed-length cutting: According to different requirements, use cutting equipment to customize different pedal lengths;

[0066] S7. Use the storage rack equipment for storage;

[0067] S8. The finished product is completed and waiting to enter the next assembly process.

[0068] Specifically, the temperature of the front section of the barrel of the extruder is set at 210°C, the temperature of the middle section of the barrel is 200°C, the temperature of the rear section of the barrel is between 190°C and 220°C, the screw speed is 65 revolutions per minute, and the extrusion pressure is between 25 MPa, and the traction speed is 0.8 meters per minute.

[0069] Specifically, the unwinding tension of the upper and lower unwinding machines is set at 160 N, the unwinding speed is about 0.9 meters per minute, and the winding speed is 0.8 meters per minute.

[0070] Specifically, the temperature of the shaping table is set at 35°C, the temperature of the cooling medium is 18°C, the vacuum degree is set at -0.085 MPa, the shaping time is 35 seconds, and the shaping pressure is set at 0.4 MPa.

[0071] Specifically, the traction tension of the tractor is set at 270 N, the distance between the traction rollers is set at 70 mm, and the traction speed range: when the extrusion speed of the extruder is 1 meter per minute, the residence time on the shaping table is 40 seconds.

[0072] Specifically, the cutting wire speed of the cutting equipment is 20 mm / s, the feed speed is 0.4 mm / revolution, the rotation speed is set at 3500 revolutions per minute, and the cutting edge angle of the tool is set at 50°.

[0073] Example 3

[0074] As Figures 1 - 3 shown, a lightweight side pedal includes a pedal body 1, a cover 2, a pedal support seat 3, and a fastening assembly 4.

[0075] Specifically, the pedal support seat 3 is installed on the pedal body 1 through the fastening assembly 4.

[0076] Specifically, the pedal body 1 further includes a main body substrate 5, a CFRT sheet 8, a side coating layer 6, and a pedal anti-slip pad 7.

[0077] Specifically, the main body substrate 5 is made of a formula with each component calculated by weight percentage, and the formula is 70% polypropylene (PP), 40% polyvinyl chloride (PVC), 15% glass fiber, 8% carbon fiber, 0.5% antioxidant, 0.8% lubricant, and 3% colorant.

[0078] A manufacturing process for a lightweight side step, the manufacturing process comprising the following steps:

[0079] S1. The formulated materials are mixed and heated and extruded by an extruder to form a main body substrate 5, and the upper and lower unwinders unwind the CFRT sheet 8, i.e., a continuous fiber reinforced thermoplastic composite sheet, synchronously;

[0080] S2. An outer anti-slip layer 7 and a side coating layer 6 raw materials are extruded by a co-extruder;

[0081] S3. Mold forming, the main body substrate 5, the CFRT sheet 8, the outer anti-slip layer 7 and the side coating layer 6 are pressed into one body through a mold;

[0082] S4. Through a sizing table, the product is cooled and sized;

[0083] S5. A tractor provides traction force to the product and pulls out the product;

[0084] S6. Fixed-length cutting: According to different requirements, a cutting device is used to customize different pedal lengths;

[0085] S7. Use a storage rack device for storage;

[0086] S8. The finished product is completed and waiting to enter the next assembly process.

[0087] Specifically, the temperature of the front section of the barrel of the extruder is set at 230 °C, the temperature of the middle section of the barrel is 210 °C, the temperature of the rear section of the barrel is between 200 °C and the head temperature is 240 °C, the screw speed is 80 revolutions per minute, the extrusion pressure is between 30 MPa, and the traction speed is 1 meter per minute.

[0088] Specifically, the unwinding tension of the upper and lower unwinders is set at 200 N, the unwinding speed is about 1 meter per minute, and the winding speed is 0.9 meter per minute.

[0089] Specifically, the temperature of the sizing table is set at 40 °C, the temperature of the cooling medium is 25 °C, the vacuum degree is set at -0.09 MPa, the sizing time is 50 seconds, and the sizing pressure is set at 0.5 MPa.

[0090] Specifically, the traction tension of the tractor is set at 300 N, the distance between the traction rollers is set at 100 mm, and the traction speed range: when the extrusion speed of the extruder is 1.5 meters per minute, the residence time of the sizing table is 55 seconds.

[0091] Specifically, the cutting wire speed of the cutting device is 130 mm / s, the feed speed is 0.5 mm / revolution, the rotation speed is set at 5000 revolutions per minute, and the tool edge angle is set at 60°.

[0092] Example 2 redesigned the detailed structure of the side pedal from the design structure, making the composition structure of the pedal simpler, the product lighter, faster, and more economical. This new process method makes the production of the side pedal simpler, reduces the complexity of the manufacturing process of the side pedal, and at the same time raises the high requirements for the mold accuracy; the manufacturing process is more convenient and fast, and greatly reduces the production and manufacturing costs, saves the cost of raw materials, reduces the usage cost and maintenance cost of customers on the vehicle, is convenient for customers to use and install, has a variety of pedal options, and does not cause pollution to the environment.

[0093] The above is only for understanding the method and core idea of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the protection scope of the rights of the present invention.

Claims

1. A lightweight side step, characterized in that: It includes a pedal body, a protective cover, a pedal support base, and a fastening assembly.

2. The lightweight side step according to claim 1, characterized in that: The pedal support base is installed on the pedal body through the fastening assembly.

3. The lightweight side pedal according to claim 1, characterized in that: The pedal body further includes a main body substrate, a side covering layer, and a pedal anti-slip pad.

4. The lightweight side step according to claim 1, characterized in that: The main body substrate is made from a formula with components by weight percentage as follows: polypropylene (PP) 50%-70%, polyvinyl chloride (PVC) 20%-40%, glass fiber 5%-15%, carbon fiber 3%-8%, antioxidant 0.1%-0.5%, lubricant 0.2%-0.8%, coloring agent 0.5%-3%.

5. The manufacturing process of a lightweight side pedal as described in any one of claims 1-4, characterized in that, The manufacturing process includes the following steps: S1. The formulated materials are mixed and heated, and then extruded into the main body substrate by an extruder. The upper and lower unwinding machines unwind the CFRT sheet, i.e., continuous fiber reinforced thermoplastic composite sheet, synchronously. S2. The co-extruder extrudes the raw materials for the outer anti-slip layer and the side covering layer. S3. Mold forming, where the main body substrate, CFRT sheet, outer anti-slip layer, and side covering layer are pressed into one body through a mold. S4. Through a sizing table, the product is cooled and sized. S5. The tractor provides traction force to the product and pulls out the product. S6. Fixed-length cutting: According to different requirements, different pedal lengths are customized using cutting equipment. S7. Storage is carried out using a storage rack device. S8. The finished product is completed and awaits the next assembly process.

6. The manufacturing process of the lightweight side step according to claim 5, characterized in that: The temperature of the front section of the extruder barrel is set at 200 - 230°C, the middle section at 190 - 210°C, the rear section at 180 - 200°C, the head temperature is between 200 - 240°C, the screw speed is 60 - 80 revolutions per minute, the extrusion pressure is between 20 - 30 MPa, and the traction speed is 0.5 - 1 meter per minute.

7. The manufacturing process of the lightweight side step according to claim 5, characterized in that: The unwinding tension of the upper and lower unwinding machines is set at 100 - 200 N, the unwinding speed is about 0.8 - 1 meter per minute, and the winding speed is 0.7 - 0.9 meter per minute.

8. The manufacturing process of the lightweight side pedal according to claim 5, characterized in that: The temperature of the sizing table is set at 30 - 40°C, the cooling medium temperature is 10 - 25°C, the vacuum degree is set at -0.08 MPa to -0.09 MPa, the sizing time is 30 - 50 seconds, and the sizing pressure is set at 0.3 - 0.5 MPa.

9. The manufacturing process of the lightweight side step according to claim 5, characterized in that: The traction tension of the tractor is set at 200 - 300 N, the distance between the traction rollers is set at 50 - 100 mm, and the traction speed range: when the extrusion speed of the extruder is 0.5 - 1.5 meters per minute, the residence time on the sizing table is 30 - 55 seconds.

10. The manufacturing process of the lightweight side step according to claim 5, characterized in that: The cutting line speed of the cutting equipment is 10 - 30 mm / s, the feed speed is 0.3 - 0.5 mm / revolution, the rotation speed is set at 3000 - 5000 revolutions per minute, and the tool edge angle is set at 40° - 60°.

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