Energy-saving racing car portal frame supporting structure and manufacturing method thereof

Abstract

The invention discloses an energy-saving racing car portal frame supporting structure and a manufacturing method thereof.The energy-saving racing car portal frame supporting structure is characterized in that a portal frame cross beam, a right portal frame side beam and a left portal frame side beam are all made of prefabricated panels, and each prefabricated panel comprises a carbon fiber plate, an aramid fiber honeycomb interlayer and an embedded aluminum block; the carbon fiber plate is prepared by uniformly dipping continuous and regular carbon fiber tows into epoxy resin to form carbon fiber prepreg and then preparing according to a set layering process; the aramid fiber honeycomb interlayer is a hexagonal honeycomb unit core material, is embedded between the carbon fiber layers and is fixed through a special binder; the pre-embedded aluminum blocks are embedded into pre-embedded sites of the carbon fiber plate, the plurality of pre-embedded aluminum blocks are symmetrically arranged left and right, and bolt holes are drilled in the pre-embedded aluminum blocks. Innovative material combination and structural design are adopted, the carbon fiber and aramid fiber honeycomb structure and the aluminum block pre-embedding technology are integrated, efficient light weight of the vehicle is achieved, a solid guarantee is provided for driving safety, and an innovative and practical solution is provided for structural optimization and upgrading of key components in the automobile field.

Description

Technical Field

[0001] The present invention relates to the technical field of energy-saving racing car parts manufacturing, and particularly to an energy-saving racing car gantry support structure and a manufacturing method thereof. Background Art

[0002] At present, as the automotive field is developing towards energy conservation and safety, the structural reinforcement of key components of energy-saving racing cars is of crucial importance. However, there are various existing technical solutions for the energy-saving racing car gantry support structure, and their disadvantages are significant.

[0003] The early simple carbon fiber gantry support structure relied on manual layup and room-temperature curing for molding. Due to the limitations of manual operation, it was difficult to precisely control the arrangement direction of carbon fibers and the resin content, resulting in extremely unstable product quality. Defects such as pores and delamination were likely to appear inside, thus significantly reducing the mechanical properties. Moreover, the room-temperature cured resin could not fully exert its bonding and strengthening effects, ultimately leading to the overall strength of the gantry being much lower than expected. During vehicle operation, it simply could not withstand various complex loads and was difficult to ensure the long-term stable driving of the energy-saving vehicle.

[0004] The hybrid metal-composite material gantry support structure (early design) introduced by some automobile manufacturers, although attempting to combine the advantages of aluminum alloy and carbon fiber, had a large difference in thermal expansion coefficients between the metal and the composite material. Under different seasons and driving conditions, frequent temperature changes would cause the adhesive to fail due to the inconsistent thermal expansion and contraction of the two, resulting in the carbon fiber plate falling off. In addition, this simple bonding method could not make the two materials work together under stress. When facing concentrated stress generated during steering knuckle installation, it mainly relied on the aluminum alloy part to bear the load, and the carbon fiber could not fully play its due role, resulting in the failure to achieve the ideal state of lightweight and high strength.

[0005] Traditional honeycomb structure gantry support structures (without aramid application) mostly used honeycomb cores made of paper or plastic materials, with very limited mechanical properties and poor resistance to high temperature and humidity. In a harsh environment, the honeycomb core was extremely easy to damage, thereby causing a sudden drop in the supporting force of the gantry. At the same time, the combination of this traditional honeycomb structure and the outer layer material was not tight enough, and it was prone to looseness under long-term vibration, unable to provide a durable and reliable support for the energy-saving vehicle, and difficult to meet the stringent usage conditions and long-life requirements of energy-saving racing cars.

[0006] In summary, the simple carbon fiber gantry has unstable quality and insufficient strength due to manual layup and room temperature curing; the hybrid metal-composite gantry is affected by the difference in the coefficient of thermal expansion of materials, and the adhesive is prone to failure and the materials are difficult to work together under force; the honeycomb core of the traditional non-aramid honeycomb structure gantry has limited performance and is not tightly combined with the outer layer material. These problems make the existing gantry support structures unable to meet the strict requirements of energy-saving racing cars for lightweight, high strength, and long-term reliable support. Summary of the Invention

[0007] The purpose of the present invention is to provide an energy-saving racing car gantry support structure and its manufacturing method. By adopting an innovative material combination and structural design method, integrating carbon fiber, aramid honeycomb structure, and embedded aluminum block technology, the problems of the existing gantry support structure in terms of quality, strength, material synergy, and environmental adaptability are solved, thereby achieving efficient lightweight of the vehicle, providing a solid guarantee for driving safety, and providing an innovative and practical solution for the structural optimization and upgrading of key components in the automotive field.

[0008] To achieve the above purpose, the present invention provides the following solutions:

[0009] An energy-saving racing car gantry support structure includes a gantry crossbeam, a right gantry side beam, and a left gantry side beam; the left gantry side beam and the right gantry side beam are respectively fixedly connected to the left and right sides of the gantry crossbeam;

[0010] The gantry crossbeam, the right gantry side beam, and the left gantry side beam are all prepared from prefabricated plates. The prefabricated plates include: carbon fiber plates, aramid honeycomb sandwich layers, and embedded aluminum blocks. The carbon fiber plates are formed by uniformly impregnating continuous regular carbon fiber tows with epoxy resin to form carbon fiber prepregs, and then prepared according to the set layup process; the aramid honeycomb sandwich layer is a hexagonal honeycomb unit core material, embedded between carbon fiber layers and fixed by a special adhesive; the embedded aluminum blocks are embedded in the embedded positions of the carbon fiber plates. Among them, multiple embedded aluminum blocks are provided, and the multiple embedded aluminum blocks are symmetrically arranged left and right. Bolt holes are drilled in the embedded aluminum blocks.

[0011] Further, the set layup process is: perform directional layup according to the force simulation results, and mainly layup at 90° in the area where the vertical pressure is concentrated, supplemented by layup at ±45°.

[0012] Further, the honeycomb pore diameter of the aramid honeycomb sandwich layer is 3 - 5 mm; the embedded aluminum blocks include a left embedded aluminum block and a right embedded aluminum block, which are respectively embedded in positions close to the left and right edges of the carbon fiber plate.

[0013] Further, a plurality of embedded aluminum blocks with drilled bolt holes are provided on the gantry cross beam, the right gantry side beam, and the left gantry side beam. The gantry cross beam, the right gantry side beam, and the left gantry side beam are fixedly connected to the vehicle body components through the cooperation of bolt holes, bolts, and nuts.

[0014] The present invention also provides a manufacturing method for the gantry support structure of an energy-saving racing car, which is used to prepare the above-mentioned gantry support structure of the energy-saving racing car, and includes the following steps:

[0015] S1. Material preparation: Select carbon fiber prepreg with high strength, high modulus, and uniformly impregnated with high-quality epoxy resin by continuous regular carbon fiber filaments as the carbon fiber board material; Select aramid honeycomb core material woven from aramid fibers into regular and fine hexagonal honeycomb units; Select aluminum alloy blocks that have been forged and finely machined, have excellent mechanical properties, and whose size and shape fit the embedded positions.

[0016] S2. Pre-forming stage - Carbon fiber layup: In the mold, plan the layup direction and number of layers according to the force simulation results of the gantry, and at the same time turn on the vacuum adsorption device to evacuate the air between layers through the fine pores of the mold, so that the carbon fiber layers are initially tightly attached to the inner wall of the mold.

[0017] S3. Pre-forming stage - Embedding aramid honeycomb core: Gently place the prefabricated aramid honeycomb core material at the predetermined position of the carbon fiber layer, ensure that the honeycomb units are arranged neatly and the upper and lower surfaces are seamlessly attached to the carbon fiber layer, and apply an appropriate amount of special adhesive at the attachment edge.

[0018] S4. Pre-forming stage - Treatment of embedded aluminum blocks: Pretreat the aluminum alloy blocks to enhance their affinity with the resin, and then embed the aluminum alloy blocks into the corresponding positions of the mold as embedded aluminum blocks to form a preform with the carbon fiber layer and the aramid honeycomb core material.

[0019] S5. Curing and forming stage - Vacuum pumping operation: Transfer the preform to a vacuum bag packaging system for sealing, and use a vacuum pump to evacuate the air to remove the remaining air, water vapor, and small molecule volatiles inside.

[0020] S6. Curing and forming stage - Static curing: Under the maintained vacuum state, place the preform in a constant temperature environment to allow the epoxy resin to fully crosslink and cure to obtain a prefabricated plate.

[0021] S7. Post-treatment and assembly stage - Grinding and trimming: After curing and demolding, use grinding equipment to remove the excess resin and burrs on the edge of the prefabricated plate to make the surface smooth and flat, meeting the requirements of dimensional tolerance and assembly accuracy.

[0022] S8. Post - processing and Assembly Stage - Drilling and Tapping: Use prefabricated plates to prepare the gantry components respectively. Drill and tap the embedded aluminum blocks on the gantry components according to the engineering drawings to prepare for connecting the body components. The gantry components include the gantry cross - beam 1, the right gantry side - beam 2, and the left gantry side - beam 3.

[0023] S9. Post - processing and Assembly Stage - Vehicle Assembly: Transport the processed gantry components to the energy - saving vehicle assembly line, and use high - strength bolts and nuts to firmly connect them to the body components in sequence according to the set torque parameters.

[0024] Further, in step S2, the planned laying direction includes: mainly laying at 90° and matching with ±45° laying in the area where the vertical pressure is relatively large.

[0025] Further, in step S4, the pre - treatment includes surface roughening and electroless plating.

[0026] Further, in step S5, the vacuum pump evacuates the air until the vacuum degree reaches - 0.09 MPa to - 0.1 MPa.

[0027] Further, in step S6, placing the pre - formed blank in a constant - temperature environment specifically means: standing at 80 - 100 °C for 4 - 6 hours.

[0028] Further, in step S9, the body components include the front - end chassis and the suspension.

[0029] According to the specific embodiments provided by the present invention, the energy - saving racing car gantry support structure and its manufacturing method provided by the present invention disclose the following technical effects:

[0030] 1. Innovatively combine carbon fiber plates, aramid honeycomb sandwich and embedded aluminum blocks; carbon fiber plates are light in weight and high in strength, significantly reducing the weight of the gantry, reducing vehicle energy consumption, and meeting the requirements of energy - saving vehicles; aramid honeycomb sandwich enhances the structural toughness, and the honeycomb structure effectively disperses stress, ensuring that the gantry can withstand complex stresses while being lightweight and guaranteeing driving safety; the embedded aluminum blocks relieve the extremely large stress when installing the steering knuckle and prevent deformation; it breaks through the technical bottleneck that it is difficult to balance lightweight and high strength in traditional structures.

[0031] 2. Select aramid honeycomb cores, which have excellent high - temperature and moisture - resistant properties, ensuring the stability of the gantry in harsh environments; optimize the composite process and adhesives, enhance the tightness of material combination, reduce structural looseness, lower maintenance costs, extend service life, and adapt to various usage scenarios.

[0032] 3. In the manufacturing method, use high - precision automated laying equipment and a quantitative grease injection system to accurately control the arrangement of carbon fibers and the resin content, reducing defects; the thermal curing process improves the resin bonding effect, enhances the strength and reliability of the gantry, enabling it to cope with complex working conditions.

[0033] 4. The lightweight gantry reduces the unsprung mass, improving the vehicle's handling and comfort. Optimizing the structure enhances the power transmission efficiency, reduces energy loss, improves the energy-saving effect and power performance, promotes the development of energy-saving vehicles towards high performance, and meets market demands.

[0034] In summary, with the aid of precision manufacturing processes, the materials in the present invention are closely connected. The carbon fiber board, aramid honeycomb sandwich, and embedded aluminum blocks are ingeniously integrated. This not only significantly reduces the vehicle weight and energy consumption but also, due to its high strength, high stability, and excellent corrosion and fatigue resistance, effectively ensures the long-term safe and stable operation of the vehicle, reduces maintenance costs, and is applicable to the production of energy-saving prototype vehicles and concept cars. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required in the embodiments. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0036] Figure 1 Schematic diagram of the overall vehicle frame external structure for an embodiment of the present invention;

[0037] Figure 2 Schematic diagram of the gantry support structure of an energy-saving racing car for an embodiment of the present invention;

[0038] Figure 3 Schematic diagram of the partial cross-sectional internal structure of the gantry side beam for an embodiment of the present invention;

[0039] Figure 4 Flowchart of the manufacturing method of the gantry support structure of an energy-saving racing car for an embodiment of the present invention;

[0040] Description of the reference numerals: 1, gantry cross beam; 2, right gantry side beam; 3, left gantry side beam; 4, bolt hole; 3-1, carbon fiber board; 3-2, aramid honeycomb sandwich; 3-3, left nut; 3-4, left bolt; 3-5, left embedded aluminum block; 3-6, right nut; 3-7, right bolt; 3-8, right embedded aluminum block. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0041] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts fall within the scope of protection of the present invention.

[0042] The purpose of the present invention is to provide an energy-saving racing gantry support structure and a manufacturing method thereof, which cleverly integrates carbon fiber plates, aramid honeycomb sandwiches and embedded aluminum blocks. The carbon fiber plates lay the foundation for lightweight, the aramid honeycomb sandwiches play the advantages of toughness and stress dispersion, and the embedded aluminum blocks resolve the extreme stress during the installation of the steering knuckle to prevent deformation.

[0043] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0044] Example 1

[0045] like Figures 1 - 3 As shown, the present invention provides an energy-saving racing car gantry support structure, comprising: a gantry crossbeam 1, a right gantry side beam 2, and a left gantry side beam 3; the left gantry side beam 3 and the right gantry side beam 2 are respectively fixedly connected to the left and right sides of the gantry crossbeam 1;

[0046] The gantry cross beam 1, the right gantry side beam 2, and the left gantry side beam 3 are all prepared from prefabricated plates, and the prefabricated plates include: a carbon fiber plate 3-1, an aramid honeycomb sandwich 3-2, and a pre-embedded aluminum block. The carbon fiber plate 3-1 is made of continuous and regular carbon fiber tows uniformly impregnated with epoxy resin to form a carbon fiber prepreg, and then prepared according to a set layering process; for example, the set layering process is: directional layering according to the force simulation results, and the vertical pressure concentration area is mainly 90° layering and supplemented by ±45° layering;

[0047] The aramid honeycomb interlayer 3-2 is a hexagonal honeycomb unit core material with a honeycomb aperture of 3-5 mm, embedded between carbon fiber layers and fixed by a special adhesive, wherein the special adhesive is epoxy resin EA9394, with a shear strength of ≥20 MPa after curing and a temperature resistance range of -55°C to 120°C; the embedded aluminum block is embedded in the embedded position of the carbon fiber plate 3-1, wherein a plurality of the embedded aluminum blocks are provided, and the plurality of embedded aluminum blocks are symmetrically arranged on the left and right, and bolt holes 4 are drilled on the embedded aluminum blocks;

[0048] The embedded aluminum block includes a left embedded aluminum block 3-5 and a right embedded aluminum block 3-8, which are respectively embedded in the positions near the left and right edges of the carbon fiber plate 3-1; the left embedded aluminum block 3-5 and the right embedded aluminum block (3-8) are pre-treated by surface roughening and chemical plating, and are precisely embedded in the positions near the left and right edges of the carbon fiber plate 3-1, and the interface bonding strength is enhanced by laser micro-texturing process. Among them, the bolt holes on the left embedded aluminum block 3-5 are used to match the left nut 3-3 and the left bolt 3-4; the bolt holes on the right embedded aluminum block 3-8 are used to match the right nut 3-6 and the right bolt 3-7.

[0049] A plurality of embedded aluminum blocks with drilled bolt holes 4 are provided on the gantry crossbeam 1, the right gantry side beam 2, and the left gantry side beam 3. The gantry crossbeam 1, the right gantry side beam 2, and the left gantry side beam 3 are fixedly connected to the vehicle body components through the cooperation of the bolt holes 4, bolts, and nuts, ensuring the stability and load-bearing capacity of the overall structure.

[0050] As Figure 4 shown, the present invention also provides a manufacturing method for the gantry support structure of an energy-saving racing car, used to prepare the above-mentioned gantry support structure of the energy-saving racing car, including the following steps:

[0051] S1. Material preparation: Select carbon fiber prepreg with high strength, high modulus, and uniformly impregnated with high-quality epoxy resin by continuous regular carbon fiber tows as the carbon fiber board material; a special aramid honeycomb core material woven with aramid fibers into regular and fine hexagonal honeycomb units; aluminum alloy blocks that have been forged and finely machined, have excellent mechanical properties, and whose size and shape fit the embedded positions.

[0052] S2. Preforming stage - Carbon fiber layup: In the mold, plan the layup direction and number of layers according to the force simulation results of the gantry. For example, in the area where the vertical pressure is relatively large, layup mainly at 90° and combine with ±45° layup. At the same time, turn on the vacuum adsorption device, and evacuate the air between layers through the fine pores of the mold to make the carbon fiber layers initially tightly fit the inner wall of the mold.

[0053] S3. Preforming stage - Embedding aramid honeycomb core: Gently place the prefabricated aramid honeycomb core material at the predetermined position of the carbon fiber layer, ensure that the honeycomb units are arranged neatly and the upper and lower surfaces are seamlessly bonded to the carbon fiber, and apply an appropriate amount of special adhesive at the bonding edge.

[0054] S4. Preforming stage - Treatment of embedded aluminum blocks: Perform surface roughening, electroless plating and other pretreatment on the aluminum alloy blocks to enhance their affinity with the resin, and then embed the aluminum alloy blocks into the corresponding positions of the mold as embedded aluminum blocks, forming a preform with the carbon fiber layer and the aramid honeycomb core material.

[0055] S5. Curing and forming stage - Vacuum pumping operation: Transfer the preform to a vacuum bag packaging system for sealing, and use a vacuum pump to evacuate the air until the vacuum degree reaches -0.09 MPa to -0.1 MPa, discharging the internal residual air, water vapor, and small molecule volatiles.

[0056] S6. Curing and forming stage - Static curing: Under the maintained vacuum state, place the preform in a constant temperature environment, such as 80 - 100 °C, and let it stand for 4 - 6 hours to fully crosslink and cure the epoxy resin to obtain a prefabricated plate.

[0057] S7. Post - processing and assembly stage - grinding and trimming: After curing and demolding, use grinding instruments to remove the excess resin and burrs from the edges of the prefabricated plates, making the surface smooth and flat, meeting the requirements of dimensional tolerance and assembly accuracy.

[0058] S8. Post - processing and assembly stage - drilling and tapping: Use prefabricated plates to prepare the gantry components respectively. Drill and tap the embedded aluminum blocks on the gantry components according to the engineering drawings to prepare for connecting the vehicle body components. The gantry components include the gantry cross - beam 1, the right gantry side - beam 2, and the left gantry side - beam 3.

[0059] S9. Post - processing and assembly stage - vehicle assembly: Transport the processed gantry components to the energy - saving vehicle assembly line, and use high - strength bolts and nuts to firmly connect them to the vehicle body chassis, suspension and other components in sequence according to the set torque parameters.

[0060] In a specific embodiment, for manufacturing the gantry of a small energy - saving racing car, the manufacturing method of the gantry support structure of the energy - saving racing car specifically includes the following steps:

[0061] (1). Material preparation: Select carbon fiber prepreg with Toray T300 grade, 3K carbon fiber tow and 32% epoxy resin matrix content in Japan; Purchase aramid honeycomb core with regular hexagon honeycomb cells from DuPont in the United States, side length 2.5mm and wall thickness 0.09mm; Use 6061 aluminum alloy that has been forged, milled (surface roughness Ra1.2μm) and anodized, and make it into a specific shape.

[0062] (2). Pre - forming stage - mold preparation: Use an aluminum alloy mold with high precision and polished inner wall (surface roughness Ra0.8μm). The mold surface is designed with vacuum adsorption holes with a hole diameter of 0.5mm and a hole pitch of 10mm arranged in a matrix.

[0063] (3). Pre - forming stage - carbon fiber layup: According to the force characteristics of the gantry of the small energy - saving vehicle, lay 8 layers of carbon fiber prepreg in the mold according to the design plan (the 0° layup accounts for 60%, and the ±45° layups each account for 20%). When laying up, turn on the vacuum adsorption system and maintain a vacuum degree of - 0.08MPa.

[0064] (4). Pre - forming stage - embedding aramid honeycomb core: Precise place the aramid honeycomb core into the mold, and apply Araldite 2015 epoxy resin adhesive to the gap between it and the carbon fiber.

[0065] (5). Pre - forming stage - embedding embedded aluminum blocks, embed the processed aluminum alloy blocks into the corresponding positions, ensuring that the embedding depth error is within ±0.2mm.

[0066] (6) Curing and forming stage - Vacuum encapsulation and static curing: Place the preformed blank into a vacuum bag for sealing, evacuate to -0.09 MPa, and then put it into a constant temperature curing oven to cure statically at 85°C for 4.5 hours.

[0067] (7) Post - treatment and assembly stage - Grinding and trimming: After curing and demolding, use 120 - mesh sandpaper with an electric grinding machine to grind the edges of the parts, remove the excess resin flash, and control the grinding depth within 0.3 - 0.5 mm.

[0068] (8) Post - treatment and assembly stage - Drilling and tapping: According to the design drawing, use a high - precision CNC drilling machine to drill M6 - sized mounting holes, and then tap with a tap. The tapping depth is 10 mm, ensuring a thread accuracy of grade 6H.

[0069] (9) Post - treatment and assembly stage - Vehicle assembly: Transfer the processed gantry parts to the assembly workshop, assemble them with relevant parts using 10.9 - grade high - strength bolts at a torque of 25 N·m. After assembly, conduct a 500 - kilometer simulated urban road condition test. The vehicle's energy consumption is reduced by 12%, and the gantry structure is stable without loosening or deformation.

[0070] In summary, in view of the deficiencies of manual layup and room - temperature curing for the simple carbon fiber gantry, this invention introduces a high - precision automated layup device, which can accurately set the arrangement direction of carbon fibers. At the same time, it cooperates with a quantitative resin injection system to strictly control the resin content, ensuring the stability of the product quality. In addition, replacing room - temperature curing with a suitable thermal curing process can enable the resin to fully exert its bonding and strengthening effects, thereby effectively improving the quality and overall strength of the product, enabling it to withstand the complex loads during vehicle operation.

[0071] Regarding the problems of adhesive failure caused by the thermal expansion and contraction differences in the hybrid metal - composite gantry, poor material co - stress, and the poor performance of traditional paper and plastic honeycomb cores and their weak bonding with the outer layer materials, this invention selects aramid to make the honeycomb core. Aramid has excellent mechanical properties, temperature resistance, and moisture resistance, which can effectively make up for the deficiencies of traditional honeycomb cores. At the same time, by optimizing the composite process and adhesives, the bonding tightness between various materials is enhanced, comprehensively avoiding the shortcomings of the existing technologies, and being able to provide reliable and durable support for energy - saving racing cars.

[0072] Specific examples are used in this article to elaborate on the principles and implementation methods of this invention. The descriptions of the above embodiments are only used to help understand the method and its core idea of this invention. At the same time, for those of ordinary skill in the art, based on the idea of this invention, there will be changes in the specific implementation methods and application scopes. In summary, the content of this specification should not be construed as a limitation to this invention.

Claims

1. An energy-saving racing car gantry support structure, characterized in that, Including: The gantry crossbeam (1), the right gantry side beam (2), and the left gantry side beam (3); the left gantry side beam (3) and the right gantry side beam (2) are respectively fixedly connected to the left and right sides of the gantry crossbeam (1); The gantry crossbeam (1), the right gantry side beam (2), and the left gantry side beam (3) are all made of prefabricated plates. The prefabricated plates include: carbon fiber plates (3-1), aramid honeycomb sandwich (3-2), and embedded aluminum blocks. The carbon fiber plates (3-1) are formed by uniformly impregnating continuous and regular carbon fiber tows with epoxy resin to form carbon fiber prepregs, and then prepared according to the set laying process; the aramid honeycomb sandwich (3-2) is a hexagonal honeycomb unit core material, embedded between carbon fiber layers and fixed by a special adhesive; the embedded aluminum blocks are embedded in the embedded positions of the carbon fiber plates (3-1). Among them, there are multiple embedded aluminum blocks, which are symmetrically arranged left and right. Bolt holes (4) are drilled in the embedded aluminum blocks.

2. The energy-saving racing car gantry support structure according to claim 1, characterized in that, The set laying process is: perform directional laying according to the stress simulation results, and mainly lay at 90° in the area where the vertical pressure is concentrated, supplemented by ±45° laying.

3. The energy-saving racing car gantry support structure according to claim 1, characterized in that, The honeycomb pore diameter of the aramid honeycomb sandwich (3-2) is 3-5 mm; the embedded aluminum blocks include a left embedded aluminum block (3-5) and a right embedded aluminum block (3-8), which are respectively embedded in the positions of the carbon fiber plate (3-1) close to the left and right edges.

4. The energy-saving racing car gantry support structure according to claim 1, characterized in that, Multiple embedded aluminum blocks with drilled bolt holes (4) are provided on the gantry crossbeam (1), the right gantry side beam (2), and the left gantry side beam (3). The gantry crossbeam (1), the right gantry side beam (2), and the left gantry side beam (3) are fixedly connected to the vehicle body components through the cooperation of bolt holes (4), bolts, and nuts.

5. A manufacturing method of a support structure for an energy-saving racing car gantry, used to prepare the support structure for an energy-saving racing car gantry according to any one of claims 1-4, characterized in that, Including the following steps: S1. Material preparation: Select carbon fiber prepregs with high strength, high modulus, and uniformly impregnated with high-quality epoxy resin by continuous and regular carbon fiber tows as the carbon fiber plate materials; Use aramid fibers to weave into a regular and fine hexagonal honeycomb unit aramid honeycomb core material; select aluminum alloy blocks that have been forged and finely machined, have excellent mechanical properties, and whose size and shape fit the embedded positions; S2. Preforming stage - Carbon fiber laying: In the mold, plan the laying direction and number of layers according to the gantry stress simulation results. At the same time, turn on the vacuum adsorption device, and evacuate the air between the layers through the fine pores of the mold to make the carbon fiber layers initially tightly fit the inner wall of the mold; S3. Preforming stage - Embedding aramid honeycomb core: Gently place the prefabricated aramid honeycomb core material at the predetermined position of the carbon fiber layer, ensure that the honeycomb units are arranged neatly and the upper and lower surfaces are seamlessly attached to the carbon fiber layer, and apply an appropriate amount of special adhesive to the attachment edge; S4. Preforming stage - Treatment of embedded aluminum blocks: Pretreat the aluminum alloy blocks to enhance their affinity with the resin, and then embed the aluminum alloy blocks in the corresponding positions of the mold as embedded aluminum blocks, forming a preform with the carbon fiber layer and the aramid honeycomb core material; S5. Curing and forming stage - Vacuum pumping operation: Transfer the preform to a vacuum bag packaging system for sealing, and use a vacuum pump to evacuate the air to remove the internal residual air, water vapor, and small molecule volatiles; S6. Solidification and Molding Stage - Static Curing: While maintaining the vacuum state, place the preformed blank in a constant-temperature environment to allow the epoxy resin to fully crosslink and cure, obtaining a prefabricated sheet; S7. Post-treatment and Assembly Stage - Grinding and Trimming: After curing and demolding, use grinding equipment to remove the excess resin and burrs on the edges of the prefabricated sheet to make the surface smooth and flat, meeting the requirements of dimensional tolerance and assembly accuracy; S8. Post-treatment and Assembly Stage - Drilling and Tapping: Use the prefabricated sheet to prepare the gantry components respectively. Drill and tap the embedded aluminum blocks on the gantry components according to the engineering drawings to prepare for connecting the vehicle body components; the gantry components include a gantry crossbeam (1), a right gantry side beam (2), and a left gantry side beam (3); S9. Post-treatment and Assembly Stage - Vehicle Assembly: Transport the processed gantry components to the energy-saving vehicle assembly line and firmly connect them to the vehicle body components in sequence with high-strength bolts and nuts according to the set torque parameters.

6. The manufacturing method of the energy-saving racing car gantry support structure according to claim 5, characterized in that, In the step S2, the planned laying direction includes: mainly laying at 90° and matching with ±45° laying in the area where the vertical pressure is relatively large.

7. The manufacturing method of the energy-saving racing car gantry support structure according to claim 5, characterized in that, In the step S4, the pretreatment includes surface roughening and electroless plating.

8. The manufacturing method of the energy-saving racing car gantry support structure according to claim 5, characterized in that, In the step S5, the vacuum pump evacuates the air until the vacuum degree reaches -0.09 MPa to -0.1 MPa.

9. The manufacturing method of the energy-saving racing car gantry support structure according to claim 5, characterized in that, In the step S6, placing the preformed blank in a constant-temperature environment specifically means: standing for 4 - 6 hours at 80 - 100 °C.

10. The manufacturing method of the energy-saving racing car gantry support structure according to claim 5, characterized in that, In the step S9, the vehicle body components include a vehicle head chassis and a suspension.

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