Integrally compression-molded hard-top tent shell for vehicle and manufacturing process of integrally compression-molded hard-top tent shell

Abstract

The invention discloses an integrally compression-molded hard top tent shell for a vehicle, which comprises a hard shell main body, the hard shell main body comprises a PHC composite substrate and a protective shell arranged outside the PHC composite substrate, and the PHC composite substrate comprises a surface glass fiber layer, a bottom glass fiber layer and a honeycomb core material arranged between the surface glass fiber layer and the bottom glass fiber layer. The invention further discloses a manufacturing process which comprises the following steps: S1, slitting the glass fiber raw material; s2, taking the unfolded honeycomb core material; s3, conveying to a spraying room for spraying a polyurethane material; s4, the prefabricated protective shell, the prefabricated first metal embedded part and the prefabricated second metal embedded part are filled; s5, performing hot-pressing shaping; s6, the blocked holes are cleaned; s7, cutting off slitter edges of the formed edges and polishing the formed edges; and S8, packaging and warehousing after visual inspection is qualified. The hard-top tent shell is integrally formed, the number of assembly parts is small, and assembly is convenient and fast; the technology is high in specificity, the manufactured hard-top tent shell can be directly used for later assembly, the overall function is complete, and practicability is high.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile accessories, and more particularly to an integrally molded high-strength and lightweight hardtop tent shell for a vehicle and a manufacturing process thereof. Background Art

[0002] Currently, hard-top tents installed on vehicle roofs are mostly made of assembled panels, which require external connectors at the joints. This results in a complex structure, cumbersome assembly, high manufacturing costs, and poor overall performance. Accordingly, the present invention provides an integrally molded hard-top tent shell for a vehicle and its manufacturing process. Summary of the Invention

[0003] The purpose of the present invention is to overcome the above-mentioned deficiencies in the prior art and to provide an integrally molded hardtop tent shell for a vehicle and a manufacturing process thereof.

[0004] To solve the above technical problems, the present invention achieves the following objectives: The present invention relates to an integrally molded hardtop tent shell for a vehicle, comprising a hard shell body, the hard shell body comprising a PHC composite substrate and a protective shell disposed outside the PHC composite substrate, the PHC composite substrate comprising a surface glass fiber layer, a bottom glass fiber layer, and a honeycomb core material disposed between the surface glass fiber layer and the bottom glass fiber layer; The hard shell body includes an end panel and a side panel arranged at the edge of the end panel and bent inwardly. The inner end surface of the end panel is embedded with a first metal embedded part, and the inner end surface of the side panel is embedded with a second metal embedded part.

[0005] The present invention is further configured as follows: a thin glass fiber lining layer is provided between the surface glass fiber layer and the honeycomb core material, and between the bottom glass fiber layer and the honeycomb core material.

[0006] The present invention is further configured such that: threaded holes and / or rivet holes are provided on the first metal embedded part and / or the second metal embedded part.

[0007] The present invention is further configured such that: the honeycomb core material is a paper honeycomb core material or an aluminum honeycomb core material.

[0008] The present invention is further configured such that: the protective shell is made of fiberglass, ABS or ASC material.

[0009] A manufacturing process for an integrally molded hardtop tent shell for a vehicle comprises the following steps: S1. Cut the fiberglass raw materials into pieces according to the preset length and width to form the surface fiberglass layer and the bottom fiberglass layer; S2. Take the honeycomb core material to complete the expansion, lay it between the surface fiberglass layer and the bottom fiberglass layer, and bind it on both sides of the edge; S3 sent to the spray room for polyurethane material spraying, complete the spraying of both ends to obtain the middle sandwich material package; S4 spraying at the same time, the mold cavity of the press mold is filled with a prefabricated protective housing, a first metal embedded part and a second metal embedded part; S5. Take the middle sandwich material package to complete the spraying, and fill it together into the mold cavity of the press mold for hot pressing and shaping to obtain end panels and side panels; S6. After removal, clean the blocked threaded holes and / or rivet holes; S7. Use special jigs for positioning and clamping, cut off the scrap edge of the formed part and polish it; S8. After passing the visual inspection, the products are packaged and put into storage.

[0010] The present invention is further configured as follows: in step S2, before binding, a thin glass fiber lining layer is further provided on the outer ends of the facing glass fiber layer and the bottom glass fiber layer.

[0011] The present invention is further configured as follows: in step S5, the holding temperature is controlled to be 90-110° C., the holding time is controlled to be 4-6 minutes, and the holding pressure is controlled to be 14.5-24.0 MPa.

[0012] In summary, the present invention has the following beneficial effects: 1. The hardtop tent shell is one-piece molded, with few assembly parts, and is easy and quick to assemble.

[0013] 2. The hardtop tent shell is built with PHC composite material, which greatly reduces the weight of the tent and makes it light and easy to carry.

[0014] 3. The hardtop tent shell is formed by hot pressing, with strong end plasticity and free and flexible shape.

[0015] 4. The manufacturing process of the hardtop tent shell is highly specialized, and the manufactured hardtop tent shell can be directly used for subsequent assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 It is a partial structural diagram of the present invention. DETAILED DESCRIPTION

[0017] In order to enable those skilled in the art to better understand the technical solutions of the present invention, the preferred embodiments of the present invention are described below in conjunction with specific examples. However, it should be understood that these descriptions are only for the purpose of further illustrating the features and advantages of the present invention, and are not intended to limit the patent claims of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0018] The present invention will be further described below with reference to the accompanying drawings and preferred embodiments.

[0019] Example 1 See also Figure 1 and Figure 2 As shown, the embodiment involves an integrally molded hardtop tent shell for a vehicle, comprising a hard shell body 100, the hard shell body 100 comprising a PHC composite substrate 101 and a protective shell 102 disposed outside the PHC composite substrate, the PHC composite substrate 101 comprising a surface glass fiber layer 1011, a bottom glass fiber layer 1012, and a honeycomb core material 1013 disposed between the surface glass fiber layer and the bottom glass fiber layer; The hard shell body 100 includes an end panel 10 and a side panel 20 bent inwardly at the edge of the end panel. A first metal embedded part 30 is embedded in the inner end surface of the end panel 10, and a second metal embedded part 40 is embedded in the inner end surface of the side panel 20.

[0020] Furthermore, a thin glass fiber lining layer 1014 is provided between the surface glass fiber layer 1011 and the honeycomb core material 1013 , and between the bottom glass fiber layer 1012 and the honeycomb core material 1013 .

[0021] Furthermore, threaded holes and / or rivet holes are provided on the first metal embedded part 30 and / or the second metal embedded part 40 .

[0022] Furthermore, the honeycomb core material 1013 is a paper honeycomb core material or an aluminum honeycomb core material.

[0023] Furthermore, the protective shell 102 is made of fiberglass, ABS or ASC material.

[0024] A manufacturing process for an integrally molded hardtop tent shell for a vehicle comprises the following steps: S1. Cut the fiberglass raw materials into pieces according to the preset length and width to form the surface fiberglass layer and the bottom fiberglass layer; S2. Take the honeycomb core material to complete the expansion, lay it between the surface fiberglass layer and the bottom fiberglass layer, and bind it on both sides of the edge; S3 sent to the spray room for polyurethane material spraying, complete the spraying of both ends to obtain the middle sandwich material package; S4 spraying at the same time, the mold cavity of the press mold is filled with a prefabricated protective housing, a first metal embedded part and a second metal embedded part; S5. Take the middle sandwich material package to complete the spraying, and fill it together into the mold cavity of the press mold for hot pressing and shaping to obtain end panels and side panels; S6. After removal, clean the blocked threaded holes and / or rivet holes; S7. Use special jigs for positioning and clamping, cut off the scrap edge of the formed part and polish it; S8. After passing the visual inspection, the products are packaged and put into storage.

[0025] Furthermore, in step S2, before binding, a thin glass fiber lining layer is added to the outer ends of the facing glass fiber layer and the bottom glass fiber layer.

[0026] Furthermore, in step S5, the holding temperature is controlled to be 90-110° C., the holding time is controlled to be 4-6 minutes, and the holding pressure is controlled to be 14.5-24.0 MPa.

[0027] In this embodiment, when aluminum honeycomb core material is selected as the raw material for making the PHC composite substrate 101, aluminum foil with a thickness of 0.03-0.07 mm is used to make the aluminum honeycomb core material, and the side length of the honeycomb cells of the prepared core material is controlled to be 4-7 mm.

[0028] Among them, when cleaning a clogged threaded hole, a rotating tap can be used; when cleaning a clogged rivet hole, a rotating drill bit can be used.

[0029] Among them, the sprayed polyurethane material is not only used as a molding raw material, but also as an adhesive.

[0030] Among them, when removing waste edges of the finished product, a milling cutter moving along a preset trajectory is used.

[0031] The present invention relates to a one-piece molded hardtop tent shell for a vehicle and its manufacturing process. The hardtop tent shell is integrally molded, requiring fewer components and facilitating quick and easy assembly. Its built-in PHC composite material significantly reduces the tent's weight, making it lightweight and easy to carry. Furthermore, the hot-pressing method allows for highly flexible end surface shape and freedom of form. The manufacturing process for this hardtop tent shell is highly specialized, allowing the resulting hardtop tent shell to be directly used for subsequent assembly, resulting in comprehensive overall functionality and high practicality.

[0032] Unless otherwise specified, in the present invention, if there are terms such as "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicating orientation or positional relationship, they are based on the orientation or positional relationship actually shown and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, the terms describing the orientation or positional relationship in the present invention are only used for illustrative purposes and cannot be understood as limiting this patent. For those skilled in the art, the specific meanings of the above terms can be understood in combination with the embodiments and according to specific circumstances.

[0033] Unless otherwise specified or limited, the terms "disposed," "connected," and "connected" in this disclosure should be understood broadly. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to direct connections or indirect connections through an intermediary; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of these terms in this disclosure based on the specific circumstances.

[0034] The above describes in detail the preferred embodiments of the present invention. It should be understood that those skilled in the art can make numerous modifications and variations based on the concepts of the present invention without inventive effort. Therefore, any technical solutions that can be derived by those skilled in the art through logical analysis, reasoning, or limited experimentation based on the concepts of the present invention and the prior art should be within the scope of protection defined by the claims.

Claims

1. An integrally molded hardtop tent shell for a vehicle, characterized in that: The hard shell body includes a PHC composite substrate and a protective shell provided outside the PHC composite substrate, wherein the PHC composite substrate includes a surface glass fiber layer, a bottom glass fiber layer, and a honeycomb core material provided between the surface glass fiber layer and the bottom glass fiber layer; The hard shell body includes an end panel and a side panel arranged at the edge of the end panel and bent inwardly. The inner end surface of the end panel is embedded with a first metal embedded part, and the inner end surface of the side panel is embedded with a second metal embedded part.

2. The integrally molded hardtop tent shell for a vehicle according to claim 1, characterized in that: A thin glass fiber lining layer is provided between the surface glass fiber layer and the honeycomb core material, and between the bottom glass fiber layer and the honeycomb core material.

3. The integrally molded hardtop tent shell for a vehicle according to claim 2, characterized in that: The first metal embedded part and / or the second metal embedded part are provided with threaded holes and / or riveted holes.

4. The integrally molded hardtop tent shell for a vehicle according to claim 3, characterized in that: The honeycomb core material is a paper honeycomb core material or an aluminum honeycomb core material.

5. The integrally molded hardtop tent shell for a vehicle according to claim 4, characterized in that: The protective shell is made of glass fiber reinforced plastics, ABS or ASC material.

6. A process for manufacturing the integrally molded hardtop tent shell for a vehicle according to claim 5, characterized in that: The following steps are involved: S1. Cut the fiberglass raw materials into pieces according to the preset length and width to form the surface fiberglass layer and the bottom fiberglass layer; S2. Take the honeycomb core material to complete the expansion, lay it between the surface fiberglass layer and the bottom fiberglass layer, and bind it on both sides of the edge; S3 sent to the spray room for polyurethane material spraying, complete the spraying of both ends to obtain the middle sandwich material package; S4 spraying at the same time, the mold cavity of the press mold is filled with a prefabricated protective housing, a first metal embedded part and a second metal embedded part; S5. Take the middle sandwich material package to complete the spraying, fill it together into the mold cavity of the press mold for hot pressing and shaping to obtain end panels and side panels; S6. After removal, clean the blocked threaded holes and / or rivet holes; S7. Use special jigs for positioning and clamping, cut off the scrap edge of the formed part and polish it; S8. After passing the visual inspection, the products are packaged and put into storage.

7. The manufacturing process of the integrally molded hardtop tent shell for a vehicle according to claim 6, characterized in that: In step S2, before binding, a thin glass fiber lining layer is added to the outer ends of the facing glass fiber layer and the bottom glass fiber layer.

8. The integrally molded hardtop tent shell for a vehicle and its manufacturing process according to claim 6, characterized in that: In step S5, the holding temperature is controlled to be 90-110° C., the holding time is controlled to be 4-6 min, and the holding pressure is controlled to be 14.5-24.0 MPa.

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