Integrated seat basin made of composite material

Abstract

The invention discloses a composite material integrally-formed seat basin which is integrally formed by CF-SMC through compression molding and comprises a front floor, a central channel, a rear floor, a front coaming, a rear coaming, a left side coaming inner plate and a right side coaming inner plate. A battery pack mounting structure integrally formed with the seat basin is arranged on the seat basin. The front floor, the central channel, the rear floor, the front wall plate, the rear wall plate, the left side wall inner plate and the right side wall inner plate are integrated into a closed basin-shaped part, the number of automobile body parts is reduced, the manufacturing cost and the automobile body weight are greatly reduced, and the endurance mileage of the electric automobile is increased; in addition, a traditional steel or aluminum battery pack installation cross beam is omitted, the battery pack installation plate is embedded in the seat basin, the manufacturing cost is further reduced, the weight of the vehicle body is reduced, and the endurance is prolonged.

Description

Technical Field

[0001] The present invention relates to the field of composite material automobile parts, and in particular to a composite material integrally formed seat basin. Background Art

[0002] Lightweight design has become a major trend in the automotive industry's technological development. For traditional fuel-powered vehicles, lightweighting reduces fuel consumption, while for new energy vehicles, it increases range. Furthermore, lightweighting can improve handling and comfort, leading to the widespread use of composite components in vehicle body structural design. To significantly reduce manufacturing costs and shorten R&D and manufacturing cycles, the integration of automotive components is also a growing trend. Current new energy vehicles require large battery packs weighing 250-500 kg, placing high demands on the strength of the mounting points. In addition to mounting points on the metal door sills on both sides of the vehicle body, metal mounting crossbeams are also required under the floor to ensure mounting point strength. However, these metal mounting crossbeams increase vehicle weight and impact range. While eliminating these crossbeams and integrating the mounting points into the floorpan can reduce weight, ensuring the battery pack's mounting strength presents significant technical challenges, especially when the floorpan is made of carbon fiber composite. Integrating the mounting points into the floorpan and ensuring their strength present significant technical challenges. Summary of the Invention

[0003] The present application provides a composite one-piece molded seat basin, which eliminates the metal mounting crossbeam under the vehicle body floor by arranging a battery pack mounting structure on the seat basin and cooperating with the metal door sill beam of the vehicle body, thereby ensuring the installation strength of the battery pack while maintaining lightweight.

[0004] To achieve the above-mentioned purpose, the present invention provides a composite one-piece seat basin, which is integrally molded from CF-SMC (carbon fiber sheet molding compound) and includes a front floor, a central channel, a rear floor, a front panel, a rear panel, a left side panel, and a right side panel inner panel; the seat basin is also provided with a battery pack mounting structure integrally molded with the seat basin.

[0005] In this embodiment, CF-SMC has excellent fluidity when heated, so that a seat basin with a complex shape can be molded in one piece. In addition, the battery pack mounting structure integrally molded with the seat basin directly replaces the battery pack mounting crossbeam that is required to be additionally set up in the existing technology, thereby significantly reducing the number of body parts and achieving weight reduction.

[0006] In another embodiment, the battery pack mounting structure includes a metal mounting plate; the metal mounting plate includes a boss and a flange surface, and a mounting hole is provided on the boss.

[0007] In this embodiment, a metal mounting plate is used to replace the traditional battery pack mounting beam. The metal mounting plate has a large flange surface and is embedded in the seat basin composite material layer. It can carry a larger load and achieve a significant weight reduction of the vehicle body while ensuring the installation strength of the battery pack, and saves installation space.

[0008] In another embodiment, a plurality of through holes are further provided on the flange surface.

[0009] In this embodiment, by setting a through hole on the flange surface, during the integral molding process of CF-SMC and the metal connecting plate, the CF-SMC can flow into the through hole after being heated. On the one hand, the connection strength between the metal connecting plate and the seat basin can be strengthened after solidification. On the other hand, it can solve the temperature difference caused by the different speeds of heating and cooling the metal plate and the CF-SMC together, as well as the possible stratification between the large flange surface and the composite material bonding surface.

[0010] In another embodiment, inclined surfaces are provided on both sides of the central channel in front of the seat basin, the angle between the inclined surfaces and the front floor is ∠A, and a metal mounting plate is provided on the inclined surfaces; the angle between the axis of the mounting hole and the flange surface is 90°-∠A.

[0011] In this embodiment, since the metal mounting plate is arranged on the inclined surfaces on both sides of the central channel in the front of the seat basin, the angle between the axis of the mounting hole and the flange surface is set to 90°-∠A, so that the axis of the mounting hole is in the same direction as the gravity. After the battery pack is installed, no stress caused by bending moment will be generated on the inclined surface, thereby improving the connection strength and stability.

[0012] In another embodiment, the flange surface and the circumference of the boss are covered with a CF-SMC material layer; and radial reinforcement ribs are provided on the mounting surface on one side of the boss along the circumference of the boss.

[0013] In this embodiment, radial reinforcement ribs are provided in the circumferential direction of the boss to enhance the strength around the mounting point.

[0014] In another embodiment, the plane of the boss is higher than the surface of the CF-SMC basin.

[0015] In this embodiment, the plane of the boss is higher than the surface of the CF-SMC seat basin, so that the CF-SMC seat basin surface will not be directly pressed when the battery panel is installed with bolts, thereby avoiding the loss of torque caused by the crushing and rupture of the CF-SMC seat basin when the battery pack fixing bolts are tightened.

[0016] In another embodiment, the seat basin is provided with a first local reinforcement layer in the front area of ​​the central channel; the seat basin is further provided with a second local reinforcement layer in the rear area of ​​the central channel and the seat mounting point area.

[0017] In another embodiment, the first local reinforcement layer and the second local reinforcement layer are arranged on the upper surface of the CF-SMC layer; the first local reinforcement layer and the second local reinforcement layer include several layers of carbon fiber unidirectional tape layers, with the transverse direction of the seat basin as 0° and the longitudinal direction as 90°, and the laying angles of the carbon fiber unidirectional tape are repeatedly arranged at 0°, 90°, 90°, and 0°.

[0018] In the above implementation plan, local reinforcement layers are set for weak strength areas such as vehicle body collision, bending stiffness, and seat installation points. The specific reinforcement layer uses carbon fiber unidirectional tape, which replaces the reinforcement plates and other components in the existing technology, thereby achieving weight reduction on the basis of improving the overall strength of the seat basin.

[0019] On the other hand, the present invention also provides a method for preparing a composite material integrally formed, comprising the steps of: Step 1: Use the mounting holes on the metal mounting plate and the bolts or pins on the mold to position and fix the metal mounting plate; Step 2: Laying the first reinforcement layer and the second reinforcement layer of carbon fiber fabric layers at corresponding positions of the mold; Step 3: Weigh the corresponding amount of CF-SMC based on the thickness and surface density of the CF-SMC composite material layer of the seat basin and place it into the mold; Step 4: compression molding; Step 5: Open the mold and remove the bolts or pins that secure the metal mounting plate to obtain a one-piece composite material seat basin.

[0020] Beneficial effects of the present invention:

[0021] (1) The seat basin part of the present invention is manufactured by the CF-SMC one-piece molding process, which integrates the front floor, central channel, rear floor, front panel, rear panel, left side panel inner panel, and right side panel inner panel into a closed basin-shaped part, thereby reducing the number of body parts, significantly reducing manufacturing costs and body weight, and increasing the cruising range of electric vehicles; (2) The present invention utilizes the designability of composite materials. The seat basin body is made of CF-SMC. Carbon fiber fabric layers are added to the weak areas in the simulation for local reinforcement. The whole is formed into one piece, eliminating the reinforcement plate and reducing the number of parts. At the same time, it also avoids the weight increase caused by the overall thickening of the parts.

[0022] (3) The present invention eliminates the traditional steel or aluminum battery pack mounting crossbeam and embeds the battery pack mounting plate into the seat basin, further reducing manufacturing costs, reducing vehicle weight, and increasing battery life; (4) The structural design of the metal connecting plate of the present invention not only satisfies the connection strength with the battery pack, but also enables the positioning of the metal insert when it is integrally formed with the seat basin. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Attachment Figure 1 This is a schematic diagram of the integrated basin structure of the present invention; Attachment Figure 2 Schematic diagram of the cross-sectional structure of the battery pack installation structure Attachment Figure 3 This is a schematic diagram of the three-dimensional structure of the metal mounting plate; Attachment Figure 4 This is a schematic diagram of the metal mounting plate structure when viewed from above; Attachment Figure 5 This is a schematic diagram of the cross-sectional structure of the metal mounting plate; Attachment Figure 6 This is a schematic diagram of the structure of the battery pack mounting structure boss on one side; Attachment Figure 7 This is a schematic diagram of the connection between the seat basin and the battery pack; Attachment Figure 8 This is a cross-sectional view of the connection between the seat basin and the battery pack; Attachment Figure 9 For attachment Figure 8 A magnified schematic diagram of the structure of part A in the middle; Attachment Figure 10 Schematic diagram of local reinforcement layer distribution; Among them: 1-seat basin; 101-front floor; 102-central channel; 103-rear floor; 104-front panel; 105-rear panel; 106-left side panel inner panel; 107-right side panel inner panel; 108-front reinforcement area of ​​central channel; 109-middle and rear reinforcement area of ​​central channel; 110-seat installation area reinforcement area; 111-slope; 112-reinforcement rib; 2-battery pack; 3-mounting plate; 31-boss; 32-flange surface; 33-wire screw sleeve; 34-through hole; 4-bolt; 5-washer; 111-slope. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making creative efforts are within the scope of protection of the present invention.

[0025] It should be noted that, in the description of the present invention, the terms "center", "upper", "lower", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention; in addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0026] Example 1

[0027] This embodiment discloses a basin integrally formed of composite material.

[0028] Combined with attachment Figure 1 A composite one-piece seat basin 1 is integrally molded from a composite material; the seat basin 1 is integrally molded from CF-SMC, and includes a front floor 101, a central channel 102, a rear floor 103, a front panel 104, a rear panel 105, a left side panel inner panel 106, and a right side panel inner panel 107; a battery pack mounting structure is provided on the seat basin 1 for installing and fixing the battery pack 2.

[0029] See attached Figure 2-5 The battery pack mounting structure includes a metal mounting plate 3, embedded within the composite material layer of the seat basin 1 and integrally formed with the seat basin 1. The metal mounting plate 3 is specifically made of AlSi10MnMg. The metal mounting plate 3 is positioned on inclined surfaces 111 on either side of the central channel 102 at the front of the seat basin 1. The metal mounting plate 3 includes a boss 31 and a flange 32. The boss 31 is provided with a mounting hole. The flange 32 is 12 to 30 mm wide, and the mounting hole is provided with a wire thread insert 33. Both the flange 32 and boss 31 are circumferentially coated with a CF-SMC composite material layer.

[0030] The flange surface 32 is also provided with a number of through-holes 34. To increase the load on the battery pack mounting structure, the metal mounting plate 3 utilizes a wider flange surface 32, which increases the contact area between the metal and the composite material, leading to the risk of interface delamination. Furthermore, the metal mounting plate 3 and the composite material are made of different materials, and the different heating and cooling rates during molding create a temperature difference, which can also lead to delamination risk. Therefore, by providing through-holes 34 on the flange surface 32, the heated CF-SMC sheet, as it flows through the mold cavity, will fill these through-holes 34, thus strengthening the connection between the metal mounting plate 3 and the seat basin 1.

[0031] The included angle between the inclined surface 111 and the front floor 101 is ∠A, and the included angle between the axis of the mounting hole of the metal mounting plate 3 and the flange surface 32 is 90°-∠A.

[0032] See attached Figure 6The mounting surface on one side of the boss 31 is provided with radial reinforcement ribs 112 along the circumference of the boss 31 .

[0033] See attached Figure 7-9 The battery pack 2 is arranged under the seat pan 1, with its two sides connected to the vehicle body door sill beams, and its front end connected to the battery pack connection structure integrally formed on the seat pan 1. Specifically, the battery pack 2 can be installed and fixed by means of bolts 4 and washers 5 in conjunction with the mounting holes of the metal mounting plate 3.

[0034] See attached Figure 9 The surface of the boss 31 of the metal mounting plate 3 protrudes from the seat surface 1 by 0.3 mm. When the seat 1 is connected to the battery pack 2, tightening the bolts 4 prevents direct compression of the CF-SMC composite seat 1, potentially causing a torque failure. This improves the connection strength and stability.

[0035] See attached Figure 10 A first local reinforcement layer is provided on the seat basin 1 in the front area 108 of the central channel; a second local reinforcement layer is also provided on the seat basin in the middle and rear area 109 of the central channel and in the seat mounting point area 110; the first local reinforcement layer and the second local reinforcement layer are provided on the upper surface of the CF-SMC layer (that is, provided on the upper surface of the seat basin 1).

[0036] The first local reinforcement layer and the second local reinforcement layer are carbon fiber unidirectional tapes, with the transverse direction of the seat basin 1 being 0° and the longitudinal direction being 90°, and the laying angles of the carbon fiber unidirectional tapes being 0°, 90°, 90°, and 0°; Furthermore, the carbon fiber unidirectional tape of the first local reinforcement layer is laid in a cyclic manner of 0°, 90°, 90°, and 0°, totaling 12 layers, and the thickness of each layer of carbon fiber unidirectional tape is 0.15 mm; the carbon fiber unidirectional tape of the second local reinforcement layer is laid in a total of 4 layers, and the thickness of each layer of carbon fiber unidirectional tape is 0.15 mm.

[0037] A simulation analysis of the seat pan 1 in this embodiment examined the failure coefficient of the carbon fiber composite material and the maximum stress of the metal connection structure under three load conditions: pitch load, braking load, and steering load. Taking the battery pack weight in grams, the pitch load analysis applied a vertical load of 4 grams; the braking load analysis applied a vertical load of 3 grams and a load in the X direction (longitudinal direction of the seat pan) of 2 grams; and the steering load analysis applied a vertical load of 3 grams and a load in the Y direction (lateral direction of the seat pan) of 2 grams. The analysis results are detailed in Table 1.

[0038] Table 1

[0039] Example 2

[0040] This embodiment discloses a composite material integrally formed basin, comprising the following steps: Step 1: Use the mounting holes on the metal mounting plate and the bolts or pins on the mold to position and fix the metal mounting plate; Step 2: Laying the first reinforcement layer and the second reinforcement layer of carbon fiber fabric layers at corresponding positions of the mold; Step 3: Weigh the corresponding amount of CF-SMC based on the thickness and surface density of the CF-SMC composite material layer of the seat basin and place it into the mold; Step 4: compression molding; Step 5: Open the mold and remove the bolts or pins that secure the metal mounting plate to obtain a one-piece composite material seat basin.

[0041] The above are preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A composite material integrally formed basin, characterized in that: The seat basin is integrally molded from CF-SMC and includes a front floor, a central channel, a rear floor, a front panel, a rear panel, a left side panel inner panel, and a right side panel inner panel; the seat basin is provided with a battery pack mounting structure integrally molded with the seat basin.

2. The composite integrally formed basin according to claim 1, characterized in that: The battery pack mounting structure includes a metal mounting plate; the metal mounting plate includes a boss and a flange surface, and a mounting hole is provided on the boss.

3. The composite integrally formed basin according to claim 2, characterized in that: A plurality of through holes are also provided on the flange surface.

4. The composite integrally formed basin according to claim 2, characterized in that: Slanted surfaces are provided on both sides of the central channel in front of the seat basin, and the angle between the inclined surface and the front floor is ∠A; the metal mounting plate is provided on the inclined surface; the angle between the axis of the mounting hole of the metal plate mounting plate and the flange surface is 90°-∠A.

5. The composite integrally formed basin according to claim 2, characterized in that: The flange surface and the circumference of the boss are covered with a CF-SMC composite material layer; the mounting surface on one side of the boss is provided with radial reinforcement ribs along the circumference of the boss.

6. The composite integrally formed basin according to claim 2, characterized in that: The surface of the boss is higher than the basin surface.

7. The composite integrally formed basin according to claim 1, characterized in that: The seat basin is provided with a first local reinforcement layer in the front area of ​​the central channel; the seat basin is also provided with a second local reinforcement layer in the rear area of ​​the central channel and the seat mounting point area.

8. The composite integrally formed basin according to claim 7, characterized in that: The first local reinforcement layer and the second local reinforcement layer are arranged on the upper surface of the CF-SMC layer; the first local reinforcement layer and the second local reinforcement layer include several layers of carbon fiber unidirectional tapes; the ply angles of the carbon fiber unidirectional tapes are repeatedly arranged at 0°, 90°, 90°, and 0°.

9. A composite integrally formed basin, based on the composite integrally formed basin according to any one of claims 1 to 8, characterized in that: Including steps: Step 1: Use the mounting holes on the metal mounting plate and the bolts or pins on the mold to position and fix the metal mounting plate; Step 2: Laying the first reinforcement layer and the second reinforcement layer of carbon fiber unidirectional tape at the corresponding positions of the mold; Step 3: Weigh the corresponding amount of CF-SMC based on the thickness and surface density of the CF-SMC composite material layer of the seat basin and place it into the mold; Step 4: compression molding; Step 5: Open the mold and remove the bolts or pins that secure the metal mounting plate to obtain a one-piece composite material seat basin.

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