Split type firewall structure applied to racing car and processing technology of split type firewall structure

Abstract

The invention relates to a split type firewall structure applied to a racing car and a processing technology thereof.The structure comprises a firewall base, the firewall base comprises left and right side flanges, a bottom flange and a main firewall supporting face, and the left and right side flanges are attached to the two side faces of the interior of a racing car single shell and are connected with the two side faces of the interior of the racing car single shell through fasteners; the bottom turnup is attached to the inner bottom face of the racing car single shell and fixed through a fastener and a fireproof sealing material, and the main firewall supporting face is provided with an obtuse-angle break angle; the edge of the firewall main body and the edge of the internal notch of the firewall base coincide and are connected through a fastener; the driver head firewall comprises an upper structure and a lower structure, the upper structure comprises a horizontal platform and a flat plate perpendicularly connected with the horizontal platform, and the two sides of the horizontal platform and the two sides of the flat plate are fixed through transition connecting plates. Compared with the prior art, installation is convenient, and maintenance is efficient and economical; light weight and high strength are realized; and the fireproof safety and the sealing performance are high.

Description

Technical Field

[0001] The present invention relates to the technical field of FSAE formula racing cars, and in particular to a split firewall structure applied to racing cars and a processing technology thereof. Background Art

[0002] The Formula SAE Student (FSAE) competition, sponsored by the Society of Automotive Engineers (SAE International), is a university-level competition for designing and manufacturing racing cars. Participating teams must independently design and manufacture a single-seat, fuel-powered Formula car that meets safety requirements, in accordance with strict competition rules and car manufacturing standards.

[0003] In FSAE racing cars, a mid-engine, rear-wheel drive layout is typically used to optimize front-to-rear weight distribution, with the engine, exhaust system, fuel supply system, and low-voltage battery all located behind the cockpit. This design exposes the racing car's firewall to extreme working conditions:

[0004] 1. High temperature tolerance: The temperature inside the engine compartment can reach over 900°C, requiring the firewall material to have excellent high temperature resistance;

[0005] 2. Puncture resistance: Fuel lines, exhaust systems, and other components may impact the firewall in the event of a malfunction, and penetration risk must be prevented.

[0006] 3. Sealing: The firewall must completely isolate the engine compartment and the cockpit to prevent high-temperature gases, fuel vapor or smoke from entering the driving area and threatening the driver's safety.

[0007] Currently, most FSAE racing cars use one-piece metal firewalls (such as steel or aluminum alloy plates). Although they can meet basic fire protection requirements, they have the following defects:

[0008] 1. Poor adaptability: The one-piece structure is difficult to match the complex curved surface inside the monocoque, and repeated trimming is required during installation, which can easily lead to poor sealing;

[0009] 2. Difficulty in maintenance: The firewall needs to be completely disassembled when overhauling the engine, which is cumbersome and easy to damage the sealing material;

[0010] 3. Weight redundancy: To meet strength requirements, thickened metal plates are usually used, which increases the weight of the vehicle and affects dynamic performance. Summary of the Invention

[0011] The purpose of the present invention is to overcome the defects of the above-mentioned prior art and provide a split firewall structure for racing cars, which is easy to install and maintain efficiently and economically; lightweight and has high strength; high fire safety and sealing.

[0012] The purpose of the present invention can be achieved by the following technical solutions:

[0013] The present invention provides a split firewall structure applied to a racing car, comprising:

[0014] The firewall base includes left and right side flanges, a bottom flange, and a main firewall support surface. The left and right side flanges are in contact with the inner side surfaces of the racing car monocoque and connected via fasteners. The bottom flange is in contact with the inner bottom surface of the racing car monocoque and fixed via fasteners and fireproof sealing material. The main firewall support surface has an obtuse angle.

[0015] The firewall body is a polygonal plate structure, the edge of the firewall body coincides with the edge of the inner notch of the firewall base and is connected by fasteners;

[0016] The driver's head firewall includes an upper structure and a lower structure. The upper structure includes a horizontal platform and a flat plate vertically connected to the horizontal platform. The horizontal platform and the flat plate are fixed on both sides by transition connecting plates. The lower structure is vertically connected to the horizontal platform.

[0017] Furthermore, the angle of the main fire wall support surface is 100° to 150°.

[0018] Furthermore, the main firewall support surface is provided with a brake pipe through hole and a wire harness installation hole, which are used for the passage and fixation of the brake pipe and the wire harness connector respectively.

[0019] Furthermore, the edge of the firewall body is connected to the inner notch edge of the firewall base via a threaded connector.

[0020] Furthermore, the geometric shapes of the firewall base and the driver's head firewall are adapted to the internal space of the FSAE racing car monocoque. The lower structure is a rectangular flat plate vertically connected to the horizontal platform.

[0021] Furthermore, the firewall structure is made of a composite material including a metal substrate and a fiber reinforcement layer.

[0022] Furthermore, the metal substrate is aluminum or aluminum alloy, and the fiber reinforcement layer includes aramid fiber and UL94-V0 grade high temperature resistant resin.

[0023] Furthermore, the edges of the firewall body and the internal notch edges are coated with fireproof edging materials.

[0024] The present invention also provides a method for manufacturing a split-type firewall structure, comprising the following steps:

[0025] S1: Prepare sheet metal stamping dies and vacuum forming dies according to the geometric shapes of the firewall base, main body and driver's head firewall respectively;

[0026] S2: Processing the metal substrate through sheet metal processing to form the intermediates of various components;

[0027] S3: Laying aramid fiber cloth on the surface of the metal substrate, coating it with high-temperature resistant resin and then vacuum curing it; preferably, the temperature is 60-120° C. and the curing time is 12-48 hours.

[0028] S4: Trim the edge of the solidified product and perform gradient polishing on the surface of the metal substrate.

[0029] Furthermore, the gradient polishing uses 500D, 1000D and 2000D abrasives in sequence.

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] (1) Convenient installation and efficient and economical maintenance: The split design allows for individual adjustment of the position of each component to adapt to the monocoque of different vehicle models, reducing assembly errors. In the event of local damage, only the corresponding split module needs to be replaced, reducing maintenance costs. The split structure allows for individual disassembly and maintenance, shortening maintenance time and eliminating the need to completely dismantle the firewall. Threaded connectors and flanged structures ensure quick positioning and tightening of split components, avoiding the problem of sealing failure caused by repeated trimming of traditional one-piece structures.

[0032] (2) Lightweight and high strength: The composite material structure (aluminum plate + aramid fiber) reduces weight by more than 30% compared to traditional metal firewalls; at the same time, the blunt angle design (100°-150°) enhances impact resistance, meeting the dual requirements of weight and strength for FSAE racing cars.

[0033] (3) High fire safety and sealing: The composite layer of aramid fiber and high-temperature resistant resin can pass the UL94-V0 test, and the edge fireproof edging further retards flame retardancy; the flange bonding structure and fireproof adhesive seal completely isolate the engine compartment and cockpit to prevent leakage of high-temperature gas and fuel vapor, complying with FSAE competition safety regulations. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a schematic structural diagram of a split firewall structure applied to a racing car according to the present invention;

[0035] Figure 2 It is a structural schematic diagram of the fire wall base of the present invention;

[0036] Figure 3 It is a structural diagram of the firewall body of the present invention;

[0037] Figure 4 It is a structural schematic diagram of the driver's head firewall of the present invention.

[0038] Figure numerals: 1-firewall base; 2-firewall body; 3-driver's head firewall; 11-left and right side flanges; 12-bottom flange; 13-main firewall support surface; 14-brake pipe through hole; 15-wiring harness mounting hole; 16-internal gap; 31-upper structure; 32-horizontal platform; 33-transition connecting plate; 34-lower structure. DETAILED DESCRIPTION

[0039] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Component models, material names, connection structures, control methods, algorithms, and other features not explicitly described in this technical solution are considered common technical features disclosed in the prior art.

[0040] A split firewall structure used in a racing car, comprising:

[0041] Firewall base 1 includes left and right side flanges 11, a bottom flange 12, and a main firewall support surface 13. The left and right side flanges 11 are attached to the inner side surfaces of the racing car monocoque and connected via fasteners. The bottom flange 12 is attached to the inner bottom surface of the racing car monocoque and fixed via fasteners and fireproof sealing material. The main firewall support surface 13 has an obtuse angle.

[0042] The firewall body 2 is a polygonal plate structure, the edge of the firewall body 2 coincides with the edge of the internal notch 16 of the firewall base 1 and is connected by fasteners;

[0043] The driver's head firewall 3 includes an upper structure 31 and a lower structure 34. The upper structure 31 includes a horizontal platform 32 and a flat plate vertically connected to the horizontal platform 32. The horizontal platform 32 and the flat plate are fixed on both sides by transition connecting plates 33. The lower structure 34 is a rectangular flat plate vertically connected to the horizontal platform 32.

[0044] In a specific embodiment, the angle of the main fire wall support surface 13 is 100° to 150°.

[0045] In a specific embodiment, the main firewall support surface 13 is provided with a brake pipe through hole 14 (φ10 mm) and a harness installation hole 15 (φ30 mm), which are used for the passage and fixation of the brake pipe and the harness connector respectively.

[0046] In a specific embodiment, the edge of the firewall body 2 is connected to the edge of the internal notch 16 of the firewall base 1 through a threaded connection.

[0047] In a specific embodiment, the geometric shapes of the firewall base 1 and the driver's head firewall 3 are adapted to the inner space of the FSAE racing car monocoque.

[0048] In a specific embodiment, the firewall structure is made of a composite material including a metal substrate and a fiber reinforcement layer.

[0049] In a specific embodiment, the metal substrate is aluminum or aluminum alloy, and the fiber reinforcement layer includes aramid fiber and UL94-V0 grade high temperature resistant resin.

[0050] In a specific embodiment, the edges of the fire wall body 2 and the edges of the internal gap 16 are coated with fireproof edging materials.

[0051] The present invention also provides a method for manufacturing a split-type firewall structure, comprising the following steps:

[0052] S1: Prepare sheet metal stamping dies and vacuum forming dies according to the geometric shapes of the firewall base 1, the main body 2, and the driver's head firewall 3;

[0053] S2: Cut and bend 1060 aluminum sheets through sheet metal processing to form intermediate components;

[0054] S3: Lay aramid fiber cloth on the surface of the metal substrate, apply UL94-V0 grade high temperature resistant resin, and then vacuum cure at a temperature of 60-120°C for 24 hours;

[0055] S4: trimming the edge of the cured product and performing gradient polishing on the surface of the metal substrate; the gradient polishing uses 500D, 1000D and 2000D abrasive pastes in sequence.

[0056] Technical effect verification:

[0057] In practical applications, the following advantages are demonstrated:

[0058] Lightweight: Composite material structure reduces weight by more than 30% compared to traditional metal firewalls;

[0059] Fire resistance: The composite layer of aramid fiber and high-temperature resistant resin has passed the UL94-V0 test, and the edge fireproof edging is further flame retardant;

[0060] Convenient maintenance: The split design shortens the engine compartment maintenance time without affecting the sealing performance.

[0061] Components not described in detail in this embodiment are all existing components that can be purchased through public channels.

[0062] The above description of the embodiments is intended to facilitate understanding and use of the invention by those skilled in the art. It will be apparent that those skilled in the art can readily make various modifications to these embodiments and apply the general principles described herein to other embodiments without requiring inventive effort. Therefore, the present invention is not limited to the above-described embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of the present invention, without departing from the scope of the present invention, should be within the scope of protection of the present invention.

Claims

1. A split firewall structure used in racing cars, characterized in that: include: The fire wall base (1) comprises left and right side flanges (11), a bottom flange (12) and a main fire wall support surface (13), wherein the left and right side flanges (11) are attached to the inner two side surfaces of the racing car monocoque and connected via fasteners, the bottom flange (12) is attached to the inner bottom surface of the racing car monocoque and fixed via fasteners and fireproof sealing material, and the main fire wall support surface (13) has an obtuse angle; The firewall body (2) is a polygonal plate-shaped structure, and the edge of the firewall body (2) coincides with the edge of the internal notch (16) of the firewall base (1) and is connected via fasteners; The driver's head firewall (3) comprises an upper structure (31) and a lower structure (34). The upper structure (31) comprises a horizontal platform (32) and a flat plate vertically connected to the horizontal platform (32). The horizontal platform (32) and the flat plate are fixed on both sides by transition connecting plates (33). The lower structure (34) is vertically connected to the horizontal platform (32).

2. The split firewall structure used in a racing car according to claim 1, characterized in that: The folding angle of the main fire wall support surface (13) is 100° to 150°.

3. The split firewall structure used in a racing car according to claim 1, characterized in that: The main fire wall support surface (13) is provided with a brake pipe through hole (14) and a wire harness installation hole (15), which are used for the passage and fixation of the brake pipe and the wire harness connector respectively.

4. The split firewall structure used in a racing car according to claim 1, characterized in that: The edge of the firewall body (2) is connected to the edge of the internal notch (16) of the firewall base (1) via a threaded connection.

5. The split firewall structure used in a racing car according to claim 1, characterized in that: The geometric shapes of the firewall base (1) and the driver's head firewall (3) are adapted to the internal space of the FSAE racing car monocoque; The lower structure (34) is a rectangular flat plate vertically connected to the horizontal platform (32).

6. The split firewall structure used in a racing car according to claim 1, characterized in that: The firewall structure is made of composite materials, including a metal substrate and fiber reinforcement layers.

7. The split firewall structure used in a racing car according to claim 6, characterized in that: The metal substrate is aluminum or aluminum alloy, and the fiber reinforcement layer includes aramid fiber and UL94-V0 grade high temperature resistant resin.

8. The split firewall structure used in a racing car according to claim 1, characterized in that: The edges of the fire wall body (2) and the edges of the internal notch (16) are both coated with fireproof edging material.

9. A method for manufacturing a split fire wall structure according to any one of claims 1 to 8, characterized in that: The following steps are involved: S1: Prepare sheet metal stamping dies and vacuum forming dies according to the geometric shapes of the firewall base (1), the main body (2) and the driver's head firewall (3); S2: Processing the metal substrate through sheet metal processing to form the intermediates of various components; S3: Laying aramid fiber cloth on the surface of the metal substrate, coating it with high-temperature resistant resin and then vacuum curing it; S4: Trim the edge of the solidified product and perform gradient polishing on the surface of the metal substrate.

10. The method for manufacturing a split-type fire wall structure according to claim 9, characterized in that: The gradient polishing uses 500D, 1000D and 2000D abrasives in sequence.

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