Side wall assembly, upper body structure assembly, frame structure and vehicle

Abstract

The application discloses a side wall assembly, an upper body structure assembly, a frame structure and a vehicle, and belongs to the technical field of vehicle parts. The side wall assembly comprises a thermal expansion pipe and a casting joint which are connected. The load bearing capacity of the side wall assembly to the top can be improved.

Description

Technical Field

[0001] This application relates to the field of vehicle component technology, and in particular to a side panel assembly, upper body structure component, frame structure, and vehicle. Background Technology

[0002] The side panels of a vehicle are critical structural components, playing a vital role in supporting roof loads (such as rollovers and roof impacts), transmitting side impact forces, and protecting the integrity of the passenger compartment. In some related technologies, the side panels have relatively low strength and poor load-bearing capacity for roof loads, potentially leading to roof collapse and passenger compartment intrusion in certain accidents, increasing safety risks. Summary of the Invention

[0003] This application provides a side panel assembly, an upper body structure component, a frame structure, and a vehicle to at least partially solve the aforementioned technical problems.

[0004] To achieve the above objectives, according to a first aspect of this application, a side panel assembly is provided, including a thermally expandable tube and a casting joint connected together.

[0005] According to a second aspect of this application, an upper body structure assembly is provided, including the aforementioned side panel assembly.

[0006] According to a third aspect of this application, a vehicle frame structure is also provided, including the aforementioned side panel assembly or the aforementioned upper body structure component.

[0007] According to a fourth aspect of this application, a vehicle is also provided, including the aforementioned side panel assembly, or including the aforementioned upper body structure assembly, or including the aforementioned frame structure.

[0008] In the side panel assembly of this application embodiment, the thermal expansion tube and the casting joint are connected in a cooperative manner. Through the casting reinforced joint and the thermal expansion tube, the external load is transmitted and distributed, which can improve the load-bearing capacity of the side panel assembly for top loads.

[0009] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0012] Figure 1 This is a block diagram of the side enclosure assembly provided in an exemplary embodiment of this disclosure;

[0013] Figure 2 This is a schematic diagram of the structure of a thermal expansion tube and casting joint provided in an exemplary embodiment of this disclosure;

[0014] Figure 3 yes Figure 2 An enlarged schematic diagram of part A in the middle;

[0015] Figure 4 yes Figure 2 Enlarged schematic diagram of part B;

[0016] Figure 5 This is a schematic diagram of another thermal expansion tube and casting joint provided in an exemplary embodiment of this disclosure;

[0017] Figure 6 yes Figure 5 An enlarged schematic diagram of section C;

[0018] Figure 7 yes Figure 5 An enlarged schematic diagram of section D in the middle;

[0019] Figure 8 yes Figure 5 An enlarged schematic diagram of section E in the middle;

[0020] Figure 9 This is a schematic diagram of another thermal expansion tube and casting joint provided in an exemplary embodiment of this disclosure;

[0021] Figure 10 yes Figure 9 Enlarged schematic diagram of section F in the middle;

[0022] Figure 11 yes Figure 9 Enlarged schematic diagram of section G in the middle;

[0023] Figure 12 yes Figure 9 Enlarged schematic diagram of section H in the middle;

[0024] Figure 13 This is a schematic diagram of the side enclosure assembly provided in an exemplary embodiment of this disclosure;

[0025] Figure 14 yes Figure 13 Enlarged schematic diagram of section I;

[0026] Figure 15 yes Figure 13 An enlarged schematic diagram of section J in the middle;

[0027] Figure 16 yes Figure 13 Cross-sectional view along the L1-L1 direction;

[0028] Figure 17 yes Figure 16 An enlarged schematic diagram of section K in the middle;

[0029] Figure 18 This is a schematic diagram of the structure of the inner plate provided in an exemplary embodiment of this disclosure;

[0030] Figure 19 yes Figure 18 An enlarged schematic diagram of section M in the middle;

[0031] Figure 20 yes Figure 18 An enlarged schematic diagram of part N in the middle;

[0032] Figure 21 yes Figure 18 An enlarged schematic diagram of the O section;

[0033] Figure 22 yes Figure 18 Enlarged schematic diagram of part P in the middle;

[0034] Figure 23 This is a schematic diagram of another thermal expansion tube and casting joint provided in an exemplary embodiment of this disclosure;

[0035] Figure 24 yes Figure 23 Enlarged schematic diagram of the Q section;

[0036] Figure 25 yes Figure 23 Enlarged schematic diagram of section R in the middle;

[0037] Figure 26 This is an exploded view of the side panel assembly provided in an exemplary embodiment of this disclosure;

[0038] Figure 27 This is a schematic diagram of the threshold and B-pillar provided in an exemplary embodiment of this disclosure;

[0039] Figure 28 This is an exploded view of a portion of the structure of the side cladding assembly provided in an exemplary embodiment of this disclosure;

[0040] Figure 29 Yes Figure 28 Further demonstration of the middle section structure.

[0041] Explanation of reference numerals in the attached figures:

[0042] 1. Side panel assembly; 10. Support assembly; 11. A-pillar; 13. B-pillar; 133. Reinforcing plate; 135. Mounting cavity; 15. Upper side panel beam; 17. Top cover; 18. Side panel; 2. Thermal expansion tube; 21. First end; 23. Second end; 20. Lower A-pillar inner panel; 70. Outer panel; 210. Sill reinforcement beam; 220. Lower A-pillar reinforcement plate; 25. Front crossbeam; 26. Middle crossbeam; 201. Bolt hole; 3731. Opening;

[0043] 30. Joint assembly; 31. A-pillar joint; 33. Beam joint; 332. First connecting end; 333. Second connecting end; 335. Third connecting end; 338. Reinforcing rib; 50. Inner panel; 51. Side panel; 53. Beam overlap; 3. Casting joint; 35. Cavity; 37. Opening; 373. C-shaped structure. Detailed Implementation

[0044] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0045] Please combine Figure 1 This application provides a side panel assembly 1, which includes a thermally expandable tube 2 and a casting joint 3 connected to each other.

[0046] In the side panel assembly of this application embodiment, the mating connection between the thermal expansion tube 2 and the casting joint 3, through the casting reinforced joint, allows the thermal expansion tube to transfer and distribute external loads, thereby improving the load-bearing capacity of the side panel assembly against top forces. Furthermore, the connected thermal expansion tube 2 and casting joint 3 also effectively improve the strength of the side panel assembly 1. Specifically, the load-bearing capacity of the side panel assembly against top forces refers to the ability of the side panel assembly (such as the connection area between the A-pillar, B-pillar, roof beam, and side panel) to resist deformation or maintain structural integrity when subjected to external forces from the top (such as rollover, top impact, heavy object pressure, etc.).

[0047] In some examples, the thickness and cross-sectional shape of the thermal expansion tube 2 can be changed according to the actual working conditions, so that the side assembly 1 can have greater strength and better load-bearing capacity for top loads, while also achieving a better balance between rigidity, elasticity and lightweight.

[0048] The casting joint 3 can be a one-piece die-cast structure.

[0049] In some embodiments, the thermal expansion tube 2 and the casting joint 3 may be arranged adjacent to each other.

[0050] Among them, the thermally expandable tube 2 is a type of pipe fitting manufactured through a thermal expansion molding process. This process involves heating the pipe material to a plastic state and then using internal pressure (such as hydraulic or pneumatic pressure) to expand it and fit it against the inner wall of a mold, thereby obtaining pipe fittings with complex cross-sectional shapes and precise dimensions. The thermally expandable tube 2 offers the following advantages: Lightweight: It allows for the design of variable diameter or wall thickness structures according to stress requirements, reducing material usage while ensuring strength. High Strength: The metal flow during the molding process improves the material's microstructure and enhances the mechanical properties of the pipe fitting. Reduced Stress Concentration: Thermally expandable tube 2 reduces stress concentration in complex geometries that are difficult to achieve with traditional welding processes, and weld points can also lead to stress concentration issues. Low Cost: Compared to multi-segment welded structures, it reduces the number of parts and assembly steps.

[0051] In some embodiments, the casting joint 3 and the thermal expansion tube 2 are overlapped, and the overlap length can be greater than 200mm, for example, 200mm, 210mm, etc.

[0052] In some embodiments, the casting joint 3 and the thermal expansion tube 2 can be connected by bolts. Specifically, the side panel assembly 1 may also include bolted connecting posts, which are mounted on the casting joint 3. The side panel assembly 1 may also include connectors, which can be bolts. Figure 3 and Figure 4 Bolts can be inserted into the bolt holes 201 of the thermal expansion tube 2 and connected to the bolted post, thereby screwing the casting joint 3 to the thermal expansion tube 2. The number of bolts can be greater than or equal to two, for example, two or three. The installed bolts can be distributed along the length of the thermal expansion tube 2. In one example, the casting joint 3 of the A-pillar joint is screwed to the thermal expansion tube 2 of the A-pillar. For example, bolts can be inserted into the casting joint 3 of the A-pillar joint and the thermal expansion tube 2 of the upper A-pillar, respectively, thereby screwing the casting joint 3 of the A-pillar joint to the thermal expansion tube 2 of the upper A-pillar. Please refer to... Figure 2 , Figure 2 The diagram illustrates the connection between the cast joint 3 of the A-pillar joint and the thermal expansion tube 2 of the upper A-pillar. Figure 2 Casting joint 3 in the figure is the casting joint 3 of the A-pillar joint. Figure 2The thermal expansion tube 2 in the figure refers to the thermal expansion tube 2 of the upper A-pillar. In one example, a receiving cavity is formed between the inner plate 50 and the outer plate 70. The casting joint 3 of the A-pillar connector can fill part of the receiving cavity. The material of the casting joint 3 of the A-pillar connector can be aluminum alloy, magnesium alloy, etc. The casting joint 3 of the A-pillar connector can be provided with bolt holes, through which bolts can be connected to the inner plate 20 of the lower A-pillar. At the same time, the contact surface between the casting joint 3 of the A-pillar connector and the inner plate 20 of the lower A-pillar can be bonded with structural adhesive, and the application direction can be along the length direction of the thermal expansion tube, thereby further improving its overall deformation capacity and connection reliability.

[0053] In some embodiments, there are multiple thermal expansion tubes 2, and at least one of the casting joints 3 is connected between two adjacent thermal expansion tubes 2. In some embodiments, there are multiple casting joints 3, and at least one of the thermal expansion tubes 2 is connected between two adjacent casting joints 3. There can be multiple thermal expansion tubes 2 and multiple casting joints 3. The support assembly 10 can include one or more of the following: A-pillar 11, B-pillar 13, and side panel 18. It is readily understood that A-pillar 11 can include thermal expansion tubes 2; B-pillar 13 can include thermal expansion tubes 2; and side panel 18 can include thermal expansion tubes 2. Further, depending on the installation location, in some embodiments, the thermal expansion tubes 2 include one or more of the following: thermal expansion tubes of the A-pillar, thermal expansion tubes of the B-pillar, and thermal expansion tubes of the side panel. The A-pillar 11 can be a pillar on either side of the windshield, supporting the roof and connecting the front panel, requiring a balance between visibility and collision strength (some models reduce blind spots by optimizing the cross-section or using high-strength steel). The B-pillar (13) can be the pillar between the front and rear doors, and it is a core force-bearing component in side collisions. It often integrates seat belt adjustment devices and window lifting mechanisms.

[0054] Please combine Figure 2 In one embodiment, the thermal expansion tube 2 of the A-pillar includes a first end 21 and a second end 23 disposed opposite to each other along its length. From the first end 21 to the second end 23, the cross-sectional area of ​​the thermal expansion tube 2 of the A-pillar first increases and then decreases. That is, along the extension direction of the thermal expansion tube 2, the cross-sectional area of ​​the thermal expansion tube 2 first increases and then decreases. In other words, the thermal expansion tube 2 has a structure that is thinner at both ends and thicker in the middle. The thinner ends of the thermal expansion tube 2 facilitate connection with the casting joint 3 of the joint assembly 30, making it easier for the casting joint 3 to wrap around the ends of the thermal expansion tube 2. The thicker middle of the thermal expansion tube 2 is designed to allow the thermal expansion tube 2 of the support assembly 10 to fully fill the receiving cavity formed between the inner plate 50 and the outer plate 70, thereby improving the overall support strength of the side panel assembly 1.

[0055] In one example, please combine Figure 2 , Figure 2The thermal expansion tube 2 in the design is the A-pillar thermal expansion tube 2. The A-pillar thermal expansion tube 2 adopts a variable cross-section design with smaller cavities at both ends and a larger cavity in the middle. This design allows for better connection with the cast joint 3 of the A-pillar connector and makes full use of space. Furthermore, bolt holes 201 can be provided at both ends of the A-pillar thermal expansion tube 2, namely the first end 21 and the second end 23, to facilitate the insertion of the connector. In one embodiment, the connector may include a bolt, which can be inserted into the bolt hole and then passed through the bolt connecting post for a tight connection.

[0056] In one example, both the casting joint 3 of the A-pillar joint and the beam joint 33 can be equipped with bolted connecting columns.

[0057] Please combine Figure 3 , Figure 4 , Figure 5 In some embodiments, at least a portion of the casting joint 3 is provided with a cavity 35, and at least a portion of the thermal expansion tube 2 is installed in the cavity 35. This further improves the overall stability and connection reliability of the side panel assembly 1. Figure 5 The diagram illustrates the connection between the beam joint 33 and the B-column. Figure 5 The thermal expansion tube 2 in the middle is the thermal expansion tube 2 of column B.

[0058] In some embodiments, the casting connector 3 further includes an opening 37 communicating with the cavity 35. The opening 37 of the casting connector 3 may be located on the side of the cavity 35 facing outwards, facilitating connection of the other side of the casting connector 3 to other structures, such as the inner panel 50. This also facilitates the installation of the end of the thermal expansion tube 2 into the cavity 35. In some examples, the casting connector 3 of the A-pillar connector may have a cavity 35 at one end facing the thermal expansion tube 2 of the A-pillar for installing a portion of the thermal expansion tube 2 of the A-pillar. Please refer to... Figure 6 In some examples, the cross-section of the end of the casting joint 3 connected to the thermal expansion tube 2 is a C-shaped structure 373. Specifically, the C-shaped structure 373 can be formed by bending the sidewall of the casting joint 3 end. The C-shaped structure 373 has an opening 3731 that communicates with the cavity 35, and this opening and the opening 37 are located on different sides of the cavity 35. In these examples, the overlap between the casting joint 3 of the A-pillar joint and the thermal expansion tube 2 of the A-pillar is a C-shaped structure design, partially enclosing the thermal expansion tube 2 of the A-pillar. In other examples, one end of the casting joint 3 of the B-pillar joint may also have a cavity 35 for installing part of the thermal expansion tube 2; this application does not limit this aspect.

[0059] In some examples, on the casting joint 3 of the one-piece die-cast structure, bolted posts can be set at certain intervals (generally 100-200mm) to achieve mechanical connection between the casting joint 3 of the one-piece die-cast structure and the side circumference 51 of the carbon fiber inner plate by bolts.

[0060] Please combine Figure 1 In some embodiments, the side panel assembly 1 includes a support assembly 10 and a connector assembly 30. The support assembly 10 includes the thermal expansion tube 2; the connector assembly 30 includes the cast connector 3. At least a portion of the cast connector 3 is connected to the thermal expansion tube 2. In these embodiments, the side panel assembly 1 can strengthen its load-bearing capacity against roof loads by using a cast reinforced connector and transmitting and distributing external loads through the thermal expansion tube 2 between the castings. This significantly improves the roof strength. According to the inventors' tests, the improvement efficiency of the roof crush test force value using a traditional sheet metal structure in related technologies is 2.5 kN / kg; while the improvement efficiency of the roof crush test force value using the embodiment of this application can reach 5 kN / kg. Compared with the traditional sheet metal structure in related technologies, the embodiment of this application significantly improves the load-bearing capacity against roof loads.

[0061] Please combine Figure 13 , Figure 14 , Figure 15 as well as Figure 16 In some embodiments, the side panel assembly 1 further includes an inner plate 50, which can be connected to the support assembly 10, the connector assembly 30, or, for example, the thermal expansion tube 2. The inner plate 50 can also be connected to a casting connector 3. The inner plate 50 is disposed inside the side panel assembly 1. Specifically, the interior of the side panel assembly 1 may refer to the side of the side panel assembly 1 facing away from the outside of the vehicle.

[0062] The inner plate 50 can be screwed to the thermal expansion tube 2. In some embodiments, bolts can pass through the thermal expansion tube 2, the casting joint 3, and the inner plate 50 to screw the inner plate 50 to the thermal expansion tube 2. The inner plate 50 may have multiple connection holes 55 for bolts to pass through. Please refer to [link to details] for further information. Figure 17 , Figure 18 , Figure 19 , Figure 20 , Figure 21 Please combine Figure 18 , Figure 18 The diagram illustrates the structure of the inner panel 50. Please refer to the diagram for further details. Figure 13 , Figure 13 An inner panel 50 is installed on the inside of the structure, which can cover the interior of the A-pillar, B-pillar, and side panel.

[0063] In some examples, the inner panel 50 may be a carbon fiber inner panel, or the inner panel 50 may be a one-piece molded inner panel.

[0064] Please combine Figure 13 and Figure 18 In some examples, the inner panel 50 may include connected side panels 51 and crossbeam overlaps 53, which may be integrally formed. The side panels 51 correspond to the side panels 18 of the support assembly, and the crossbeam overlaps 53 correspond to the crossbeam joints 33 of the support assembly. The side panels 51 and crossbeam overlaps 53 are integrally formed into the inner panel 50. The inner panel 50 may be a carbon fiber inner panel, offering high molding flexibility.

[0065] Furthermore, the inner plate 50 can form a cavity structure, which can specifically correspond to the crossbeam joint 33. The casting joint 3 of the crossbeam joint can be installed inside the cavity structure. The casting joint 3 of the crossbeam joint can be an integral die-cast structure, thereby enhancing the performance of the crossbeam joint.

[0066] Please combine Figure 5 , Figure 13 In some embodiments, the support assembly 10 includes a B-pillar 13, the B-pillar 13 including the thermal expansion tube 2, and the thermal expansion tube 2 of the B-pillar is connected to the inner plate 50.

[0067] Specifically, the connection between the thermal expansion tube 2 of the B-pillar and the inner plate 50 can be achieved by bolting through pre-drilled holes in the inner plate 50 and the thermal expansion tube 2 of the B-pillar. In some embodiments, the thermal expansion tube 2 of the B-pillar can be a conformal thermal expansion tube 2. In addition to bolting, the connection between the thermal expansion tube 2 of the B-pillar and the inner plate 50 can also be strengthened by applying structural adhesive. The adhesive should be applied along the height of the B-pillar 13, and the number of applications can be greater than or equal to two, such as two or three. The structural adhesive should be evenly distributed along the width of the B-pillar 13.

[0068] Please combine Figure 15 as well as Figure 16 , Figure 17 In some embodiments, the B-pillar 13 further includes a reinforcing plate 133 connected to the inner panel 50. The reinforcing plate 133 may be configured to face outwards. The reinforcing plate 133 may be a thermoformed reinforcing plate.

[0069] In some embodiments, a mounting cavity 135 is formed between the reinforcing plate 133 and the inner plate 50, and at least a portion of the thermal expansion tube 2 of the B-pillar is installed in the mounting cavity 135. Figure 17 The thermal expansion tube 2 in the middle is the thermal expansion tube 2 of column B.

[0070] The reinforcing plate 133 can be a thermoformed reinforcing plate. The thermal expansion tube 2 of the B-pillar and the reinforcing plate 133 can be connected by plug welding. The length of each plug weld can be greater than or equal to 30mm, such as 30mm or 40mm. The weld points are distributed along the height direction of the B-pillar 13, and the spacing is determined according to the welding process, so as to avoid mutual interference between adjacent weld points. The number of plug welds along the height direction of the B-pillar 13 is greater than or equal to 2, such as two or three, and can be evenly distributed along the width direction of the B-pillar 13. Through the above connection method, the reinforcing plate 133, the thermal expansion tube 2 of the B-pillar, and the inner plate 50 are connected into a whole structure that works together to bear the load. In this way, the connection form of the thermal expansion tube 2 with the carbon fiber inner plate 50 and the thermoformed reinforcing plate 133 overcomes the defect of poor overall co-force-bearing deformation capacity of the thermal expansion tube 2 and the inner and outer plates of the B-pillar made of different materials, and can effectively reduce the stress at the joint of the B-pillar 13. Thus, on the one hand, the B-pillar 13 structure can be further strengthened by the thermally expanded tube 2, which has better overall integrity; on the other hand, the thermally expanded tube 2 of the B-pillar 13 shares the force with the inner and outer plates, which can effectively reduce the pressure at the stop position of the B-pillar 13. In this embodiment, for the B-pillar 13, a key structure that affects both top pressure and side impact performance, a thermoformed reinforcing plate 133 can also be provided on the outside of the thermally expanded tube 2. The upper part of the reinforcing plate 133 can be bolted to the casting joint 3 at the top of the B-pillar 13, the lower part can be welded to the sill reinforcing plate, and the middle part can be plug-welded to the thermally expanded tube 2.

[0071] Please combine Figure 17 and Figure 27 In some embodiments, the stop position of the B-pillar 13 is a thermoformed reinforcing plate 133 and a carbon fiber inner plate 50, which can be connected by adhesive bonding. This arrangement concentrates the connection of the thermoformed reinforcing plate 133, the thermal expansion tube 2 of the B-pillar, and the carbon fiber inner plate 50 in the middle of the B-pillar 13. This reduces the stress at the stop position of the B-pillar 13, prevents adhesive failure, and improves the overall top pressure bearing capacity of the structure.

[0072] In this embodiment, the casting joints (e.g., the crossbeam joint 33), the carbon fiber inner plate 50, and the carbon fiber inner plate outer plate 70 of the side panel assembly all possess high strength, and the joint assembly 30 also exhibits good bending and torsional stiffness. Furthermore, the side panel 51 and the crossbeam overlap 53 are integrally molded into the inner plate 50. Specifically, the crossbeam overlap 53 can serve as the lower end plate of the crossbeam joint, and the side panel 51 can serve as the inner side panel. The integral carbon fiber inner plate, formed by integrating the lower end plate of the crossbeam joint with the inner side panel, can be connected to the casting joint using both bolts and adhesive. This structural form overcomes the shortcomings of traditional sheet metal structures where the crossbeam end plate and the inner side panel are only connected by weld points, resulting in a single connection method and the weld point being located in a high-stress area.

[0073] In some examples, pillar A11 may include an upper pillar A and a lower pillar A. Please refer to the relevant documentation. Figure 2 The upper A-pillar includes thermal expansion tube 2. Figure 2 The thermal expansion tube 2 in the middle is the thermal expansion tube 2 of the upper A-pillar. The contact position between the thermal expansion tube 2 of the upper A-pillar and the outer panel 70 and the inner panel 50 can be reinforced by structural adhesive to ensure that the connection between the thermal expansion tube 2 of the upper A-pillar and the outer panel 70 and the carbon fiber inner panel 50 is coordinated to ensure that they bear the force in a coordinated manner.

[0074] Please combine Figure 27 , Figure 27 The side panel structure assembly is shown, in which the lower A-pillar reinforcing plate 220 is assembled with the lower A-pillar inner plate 20, and the upper part is filled with a cast joint 3 for the A-pillar joint, which can be set as an integral casting. The cast joint 3 of the A-pillar joint can be connected to the A-pillar inner plate 20 and the A-pillar reinforcing plate 220 by bolts. In one example, the upper part of the A-pillar inner plate 20 and the A-pillar reinforcing plate 220 are connected by welds at the front and rear stop positions, which can be done by welding points, etc.; the lower part overlaps with the sill reinforcing beam 210, which can be connected by hot-melt self-tapping rivet technology (FDS), etc. The reinforcing plate 133 is connected to the sill reinforcing beam 210. The reinforcing plate 133 can be a B-pillar thermoformed reinforcing plate.

[0075] Please combine Figure 28 and Figure 29 In some examples, the upper body structure assembly may include a roof 17, to which the thermal expansion tube 2 of the side panel is connected on the roof-facing side. The roof 17 covers the inner panel 50 and the outer panel, forming a receiving chamber between the roof 17 and the inner panel 50, and between the outer panel and the roof 17. The support assembly 10 and the connector assembly 30 may both be located within the receiving chamber.

[0076] In some examples, the top cover 17 can specifically be a one-piece carbon fiber top cover.

[0077] In some examples, please combine Figure 28 and Figure 29 , Figure 29 The image shows a partially enlarged view of the connection between the inner panel 50 and the front and middle crossbeams. The through cavity formed by the outer panel 70, inner panel 50, front crossbeam 25, and middle crossbeam 26 can be filled with a casting joint 3 for the crossbeam connector. Specifically, the casting joint 3 for the crossbeam connector can be an integrated casting of the B-pillar and crossbeam connector. The front crossbeam 25 can be a carbon fiber front crossbeam, and the middle crossbeam 26 can be a carbon fiber middle crossbeam. The inner panel 50 can be a one-piece carbon fiber inner panel.

[0078] During installation, the thermal expansion tube 2 of the support assembly 10, the casting joint 3 of the joint assembly 30, and the inner plate 50 can be connected together as a whole using bolts. Then, the reinforcing plate 133 is connected, followed by the outer plate 70, and finally the top cover 17. Here, the top cover 17 refers to the roof of the vehicle.

[0079] Please combine Figure 9 , Figure 9 The thermal expansion tube 2 in the design refers to the thermal expansion tube 2 of the side circumference, specifically the thermal expansion tube 2 of the upper side beam 15 of the side circumference. The thermal expansion tube 2 of the side circumference can be bolted to the inner plate 50 through bolt holes located on the side, and the thermal expansion tube 2 of the side circumference can be bolted to the carbon fiber top cover 17 through bolt holes located at the top. During the bolting connection, the thermal expansion tube 2 of the upper side beam 15 of the side circumference can be tightly fitted to the top cover 17 and the inner plate 50. In some examples, structural adhesive can be used to reinforce the connection, and the number of adhesive strips can be greater than or equal to two, such as two or three strips, thereby enabling the thermal expansion tube 2 of the upper side beam 15 of the side circumference to be bonded to the outer plate 70 of the side circumference 18 and the carbon fiber inner plate 50 through adhesive bonding. In some embodiments, the carbon fiber inner panel 50 and the thermal expansion tube 2 of the side upper beam 15 are screwed together. The thermal expansion tube 2 can be glued to the outer panel 70 of the side 18 and the carbon fiber inner panel 50, thereby avoiding the need for opening holes in the outer panel of the side 18, making the shape more beautiful and the sealing and waterproof performance better.

[0080] Please combine Figure 26 In some embodiments, the side panel assembly 1 further includes an outer panel 70, which is connected to the reinforcing plate 133, which is located between the outer panel 70 and the inner panel 50.

[0081] In some embodiments, the B-pillar location utilizes a structure consisting of a carbon fiber outer plate, a thermoformed reinforcing plate, a thermally expanded tube, and a carbon fiber inner plate. The carbon fiber outer plate and the thermoformed reinforcing plate can be glued together, the thermoformed reinforcing plate and the thermally expanded tube can be plug-welded at their contact points, and the thermally expanded tube and the carbon fiber inner plate can be screwed together at their contact points. This design results in a smaller overall thickness, less space occupation, and a tighter connection, leading to better overall integrity. In these embodiments, placing the key connection area in the middle of the B-pillar effectively reduces stress at the joint and mitigates the problem of reduced load-bearing capacity due to joint delamination under external loads. Please refer to... Figure 26 Furthermore, the lower part of the thermal expansion tube 2 of the B-pillar does not extend to the position of the sill reinforcement beam 210. Instead, the lower part of the thermal expansion tube 2 of the B-pillar is spaced apart from the sill reinforcement beam 210. Specifically, the lower part of the thermal expansion tube 2 of the B-pillar can extend to the upper area of ​​the lower opening of the inner panel. In this way, the strength of the lower part of the B-pillar meets the requirements, while also taking into account the energy absorption function required of the lower part of the B-pillar in side-impact conditions. In addition, it also facilitates the installation of seat belts, pipelines, etc.

[0082] Please combine Figure 26 , Figure 26 The image specifically shows the structure of the lower A-pillar inner panel 20, the sill reinforcement beam 210, the lower A-pillar reinforcement plate 220, and the outer panel 70. The outer panel 70 can be a one-piece carbon fiber side panel. This one-piece carbon fiber side panel can be a structure formed by fastening to the thermal expansion tube 2 and the casting joint 3, etc., and is connected to the structure formed by the thermal expansion tube 2 and the casting joint 3, etc., through structural adhesive, rivets, etc.

[0083] In some embodiments, the outer panel may be a carbon fiber outer panel 70.

[0084] Please combine Figure 9 , Figure 9 The diagram illustrates the structural relationship between the cast joint 3 of the crossbeam joint and the thermal expansion tube 2 of the side circumference. Figure 9 The thermal expansion tube 2 in the middle is the thermal expansion tube 2 of the side circumference. In some embodiments, the support assembly 10 also includes a side circumference 18, which includes the thermal expansion tube 2.

[0085] In some embodiments, the thermal expansion tube 2 of the side circumference can be connected to the inner plate 50.

[0086] Please combine Figure 7 , Figure 8 In some embodiments, the side panel assembly 1 further includes a crossbeam, and the joint assembly 30 includes a crossbeam joint 33 connected to the crossbeam, the crossbeam joint 33 including the casting joint 3. Please refer to... Figure 28The crossbeams may specifically include a front crossbeam 15 and a middle crossbeam 26. The crossbeam joint 33 may specifically include a joint at the overlap position between the front crossbeam and the side panel 18, and a joint at the overlap position between the B-pillar 13 and the middle crossbeam. In one embodiment, a receiving cavity is formed between the inner panel 50, the outer panel, and the roof 17. The crossbeam joint 33 can fill part of the space in the receiving cavity. The crossbeam joint 33 has good bending stiffness and local compressive strength, and can effectively resist the pressure exerted on the vehicle body by the pressure plate during the top strength test.

[0087] In some embodiments, the inner panel 50 includes a beam overlap portion 53, which may specifically be a beam overlap plate. The beam overlap plate can be connected to a beam and to an A-pillar 11. A beam joint can be connected between the beam and the A-pillar 11. This structure can be arranged at the top pressure position, which can further improve the rigidity of the side panel assembly 1.

[0088] Furthermore, the inner panel 50, outer panel 70, and top cover 17 can be made of carbon fiber, thus making them less susceptible to the limitations of sheet metal stamping processes.

[0089] In some embodiments, the casting joint 3 of the beam connector is provided with reinforcing ribs 338. The casting joint 3 includes a first side and a second side opposite to each other. The reinforcing ribs 338 are connected to the first side and extend in a direction away from the second side. The side assembly 1 includes an inner plate 50, which is connected to the second side. By providing reinforcing ribs 338, the load-bearing capacity and weight reduction are achieved.

[0090] In some embodiments, the thickness of the material in the area where the casting joint 3 overlaps with the thermal expansion tube 2 can be appropriately reduced. In the overlapping area, the thermal expansion tube 2 and the casting joint 3 are connected by bolts, and the thermal expansion tube 2 can serve as the main load-bearing structure. In some embodiments, the thermal expansion tube 2 is not of uniform thickness; it can be designed with thicker edges using TRB (Tailor Rolled Blanks) technology, making the material distribution of the thermal expansion tube 2 more reasonable and achieving further weight reduction.

[0091] The reinforcing rib 338 of the casting joint 3 of the crossbeam connector has a flat contact surface with the inner plate 50, facilitating the connection between the casting joint 3 and the inner plate 50. The connection method can be bolting, adhesive bonding, etc. The inner plate 50 can be a carbon fiber inner plate. The reinforcing rib 338 faces outwards.

[0092] In some embodiments, the casting joint 3 of the beam connector and the inner plate 50 can be screwed together. The casting joint 3 of the beam connector can be provided with bolt connection posts for bolts to be inserted. There can be multiple bolt connection posts, and the spacing between two adjacent bolt connection posts can be 100-200mm. Specifically, it can be determined according to different top pressure test target values. The connection can be tightened after the bolts are inserted.

[0093] In some embodiments, the casting joint 3 of the beam connector is also provided with a bolt connection post at the position where it extends into the front beam 25 and the B-pillar 13, so as to facilitate bolt connection.

[0094] In some embodiments, the casting joint 3 of the beam connector is also provided with bolt connection posts at the positions where it extends into the front beam 25, the middle beam 26, and the B-pillar 13, to facilitate bolt connection.

[0095] The overlapping position of the casting 3 with the thermal expansion tubes of the upper A-pillar, the B-pillar, and the side wall is similar to the connection form between the thermal expansion tube and the casting joint at the A-pillar joint 31, and the casting partially wraps around the thermal expansion tube 2.

[0096] In some embodiments, the second side is a plane. The contact point between the casting joint 3 and the inner panel 50 is a mating plane. Setting it to a plane allows for reinforcement of the connection between the casting joint 3 and the vehicle body using structural adhesive.

[0097] Please combine Figure 9 , Figure 10 , Figure 11 ,as well as Figure 12 In some embodiments, the casting joint 3 of the beam joint includes a first connecting end 332, the support assembly 10 includes an A-pillar 11, the A-pillar 11 includes the thermal expansion tube 2, and the first connecting end 332 is connected to the thermal expansion tube 2 of the A-pillar.

[0098] Please combine Figure 23 , Figure 23 The diagram illustrates the connection between the cast joint 3 of the beam connector and the thermal expansion tube 2 of the A-pillar. Figure 23 Casting joint 3 in the figure is the casting joint 3 of the beam joint. Figure 23 The thermal expansion tube 2 in the middle is the thermal expansion tube 2 of column A.

[0099] Please combine Figure 22 , Figure 23 , Figure 24 The casting joint 3 of the beam joint includes a second connecting end 333, the support assembly 10 includes a B-pillar 13, the B-pillar 13 includes the thermal expansion tube 2, and the second connecting end 333 is connected to the thermal expansion tube 2 of the B-pillar.

[0100] Please combine Figure 9 , Figure 10 , Figure 11 as well as Figure 12 The casting joint 3 of the beam connector includes a third connecting end 335, the support assembly 10 includes a side wall 18, the side wall 18 includes the thermal expansion tube 2, and the third connecting end 335 is connected to the thermal expansion tube 2 of the side wall. The beam connector 33 can be an integral structure.

[0101] Please combine Figure 25 In one example, the casting joint 3 of the crossbeam connector has a shape that closely fits the inner panel 50 on the side closest to the inner panel 50. The casting joint 3 is bonded to the carbon fiber sidewall using structural adhesive, forming a composite connection of adhesive and mechanical bonding to ensure that the casting and carbon fiber structure share the load and deformation. Unlike traditional sheet metal structures where material utilization considerations lead to non-through-cavity connections between the crossbeam and sidewall joint cavities, and the upper and lower overlapping end plates of the crossbeam are only connected to the inner panel of the sidewall structure via weld points, the casting joint 3 of the crossbeam connector in this embodiment adopts an integrated die-cast structure. The casting joint 3 of the crossbeam connector can be placed in the through-cavity formed between the inner and outer panels, thus forming a high-strength joint structure, which greatly improves the rigidity of the vehicle body structure and the strength performance of the roof.

[0102] The casting joint 3 of the beam connector connects the beam, A-pillar 11, and B-pillar 13 into a whole, achieving the purpose of coordinated force distribution. Specifically, the casting joint 3 of the beam connector may further include a fourth connecting end, which connects to the front beam, and a fifth connecting end, which connects to the middle beam. The first end 21 of the thermal expansion tube 2 of the A-pillar can be connected to the casting joint 3 of the upper A-pillar. The second end 23 of the thermal expansion tube 2 of the A-pillar can be connected to the first connecting end 332 of the casting joint 3 of the beam connector. The second connecting end 333 is connected to the upper section of the B-pillar 13. Thus, in some embodiments, the casting joint 3 of the beam connector can connect the front beam, upper A-pillar, middle beam, and upper section of the B-pillar 13 into a whole, achieving the purpose of coordinated force distribution.

[0103] In one example, the length of the casting joint 3 of the aforementioned beam connector extending into the beam can be greater than or equal to 200mm, for example, 200mm, 210mm, etc. The beam can include a front beam, a middle beam, etc., and the portion of the casting joint 3 extending into the beam is also provided with reinforcing ribs 338 and bolt connection posts. The bolt connection posts can be arranged along the width direction of the beam. The bolt arrangement positions can divide the width of the beam into three equal parts. In one example, the lap plates of the front beam and the middle beam can have holes drilled at the corresponding positions of the bolt connection posts for bolt connection. In one example, the contact surface between the casting joint 3 of the beam connector and the lap plate of the beam is a flat surface, which can be reinforced by applying structural adhesive. The length direction of the structural adhesive can be consistent with the length direction of the beam, and the number of adhesive strips can be greater than or equal to two, for example, two or three strips.

[0104] In one example, the support assembly 10 may include a B-pillar 13, which may include a thermal expansion tube 2, specifically a conformal thermal expansion tube 2. The length of the casting joint 3 of the aforementioned beam connector extending into the B-pillar 13 may be greater than or equal to 250 mm, for example, 250 mm, 260 mm, etc. The number of bolts may be greater than or equal to two, for example, two or three, etc. The bolts may be arranged and installed along the height direction of the B-pillar 13 to ensure a reliable connection between the casting joint 3 of the beam connector and the thermal expansion tube 2 of the B-pillar. Simultaneously, the thermal expansion tube 2 of the B-pillar and the extended portions of the casting joint 3 of the beam connector are tightly fitted, and at least two coats of structural adhesive may be applied, for example, two or three coats, etc. The length of each adhesive strip may be equal to the overlap length between the casting joint 3 of the beam connector and the thermal expansion tube 2 of the B-pillar. The structural adhesive may be distributed along the width direction of the B-pillar 13.

[0105] Please combine Figure 13 , Figure 13 The diagram illustrates one structure of the side panel assembly 1. Figure 13 The side panel assembly 1 includes an A-pillar 11, a B-pillar 13, and a side panel 18. The A-pillar connector 31, the thermal expansion tube 2 of the A-pillar 11, the crossbeam connector 33, and the thermal expansion tube 2 of the side panel are connected in sequence. At the same time, the crossbeam connector 33 is also connected to the thermal expansion tube 2 of the B-pillar 13.

[0106] In this embodiment, the joint assembly 30 includes a cast joint 3, at least a portion of which is connected to the thermal expansion tube 2, thereby reinforcing the joint position through the casting. Each cast joint 3 can be connected in series via the thermal expansion tube 2 to form an integral side panel assembly 1. The side panel assembly 1 has at least the following characteristics: First, the overlap between the cast joint 3 and the thermal expansion tube 2 is set in a semi-enclosed form, which facilitates assembly line production and improves the convenience of assembly of the side panel assembly 1 of the vehicle body; second, the semi-enclosed form and the structure facing the same direction as the reinforcing rib 338 (towards the outer side of the vehicle body) can meet the process requirements of the casting draft angle.

[0107] The embodiments described in this application have the following effects:

[0108] First, the side panel assembly 1 proposed in this application integrates a casting, hot-formed steel, a thermally expanded tube 2, and a carbon fiber side panel 18, with an inner plate 50 and an outer plate 70. Through the above structure, a high level of lightweighting can be achieved, and good top pressure and side impact protection capabilities can be obtained.

[0109] Secondly, in the side panel assembly 1 proposed in this application, carbon fiber is used as the inner plate 50 and outer plate 70 of the side panel 18, and a thermal expansion tube 2 is set in the middle for a firm bolt connection with the casting. The bending load-bearing capacity is stronger than that of the casting and sheet metal structures in related technologies. Moreover, the casting in this application is located at the lap joint of the front crossbeam and the side panel 18, serving to pass through and support the joint cavity.

[0110] Thirdly, in the side panel assembly 1 proposed in this application, the joint assembly 30 includes a cast joint 3; in other words, at least a portion of the joint assembly 30 can be a cast structure. The cast joint 3 serves two purposes: firstly, it connects the thermal expansion tube 2 to form the vehicle body structural frame; secondly, the cast joint 3 can include a through-type, integral infill reinforcement structure, which can better improve the joint's resistance to bending and local loads.

[0111] According to a second aspect of this disclosure, an upper body structure assembly is provided, including the aforementioned side assembly 1. The upper body structure assembly includes the aforementioned side assembly 1 and has all the beneficial effects of the aforementioned side assembly 1, which will not be elaborated further herein.

[0112] According to a third aspect of this disclosure, a vehicle frame structure is provided, including the aforementioned side assembly 1 or the aforementioned upper body structure assembly. This vehicle frame structure possesses all the beneficial effects of the aforementioned side assembly 1 or the aforementioned upper body structure assembly, which will not be elaborated further herein.

[0113] According to a fourth aspect of this disclosure, a vehicle is provided that includes the aforementioned side panel assembly 1, or the aforementioned upper body structure assembly, or the aforementioned frame structure. This vehicle possesses all the beneficial effects of the aforementioned side panel assembly 1, the aforementioned upper body structure assembly, or the aforementioned frame structure, which will not be elaborated further herein.

[0114] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0115] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0116] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0117] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A side panel assembly, characterized in that, include: A-pillar, B-pillar, and side panel, wherein the A-pillar, the B-pillar, and the side panel all include thermal expansion tubes; Front crossbeam and middle crossbeam; as well as A beam joint, the beam joint including a casting joint, the casting joint adopting an integral die-cast structure; The casting joint of the crossbeam connector includes a first connecting end, a second connecting end, a third connecting end, a fourth connecting end, and a fifth connecting end. The first connecting end is connected to the thermal expansion tube of the A-pillar, the second connecting end is connected to the thermal expansion tube of the B-pillar, the third connecting end is connected to the thermal expansion tube of the side wall, the fourth connecting end is connected to the front crossbeam, and the fifth connecting end is connected to the middle crossbeam.

2. The side panel assembly according to claim 1, characterized in that, At least a portion of the casting joint has a cavity, and at least a portion of the thermal expansion tube is installed in the cavity.

3. The side panel assembly according to claim 2, characterized in that, The casting joint is further provided with an opening communicating with the cavity; and / or The opening of the casting joint is located on the side of the cavity facing outwards from the vehicle.

4. The side panel assembly according to claim 1, characterized in that, The thermal expansion tube and the casting joint are arranged adjacent to each other; and / or The thermal expansion tubes are multiple, and at least one of the casting joints is connected between two adjacent thermal expansion tubes; and / or The casting joints are multiple, with at least one of the thermal expansion tubes connected between two adjacent casting joints; and / or The cross-section of the end of the casting joint connected to the thermal expansion tube is C-shaped; and / or The casting joint is threaded to the thermal expansion tube; and / or The thermal expansion tube includes a first end and a second end disposed opposite to each other along its length, and the cross-sectional area of ​​the thermal expansion tube first increases and then decreases from the first end to the second end.

5. The side panel assembly according to claim 1, characterized in that, The side panel assembly includes: Support assembly, including the thermally expanded tube; A connector assembly, including the cast connector.

6. The side panel assembly according to claim 5, characterized in that, The side panel assembly also includes an inner panel, which is connected to the support assembly and / or the joint assembly, and is disposed inside the side panel assembly.

7. The side panel assembly according to claim 6, characterized in that, The inner panel is a carbon fiber inner panel; and / or The inner panel is a one-piece molded inner panel.

8. The side panel assembly according to claim 7, characterized in that, The inner panel includes connected side panels and crossbeam overlaps.

9. The side panel assembly according to claim 6, characterized in that, The support assembly includes a B-pillar, the B-pillar includes the thermal expansion tube, and the thermal expansion tube of the B-pillar is connected to the inner plate.

10. The side panel assembly according to claim 9, characterized in that, The B-pillar also includes a reinforcing plate, which is connected to the inner plate.

11. The side panel assembly according to claim 10, characterized in that, The reinforcing plate is configured to face outwards from the vehicle; and / or A mounting cavity is formed between the reinforcing plate and the inner plate, and at least a portion of the thermal expansion tube of the B-pillar is installed within the mounting cavity; and / or The reinforcing plate is a thermoformed reinforcing plate.

12. The side panel assembly according to claim 10, characterized in that, The side panel assembly also includes an outer panel, which is connected to the reinforcing plate.

13. The side panel assembly according to claim 12, characterized in that, The reinforcing plate is located between the outer plate and the inner plate; and / or The outer panel is a carbon fiber outer panel.

14. The side panel assembly according to claim 5, characterized in that, The side panel assembly also includes an inner panel, and the thermal expansion tube of the side panel is connected to the inner panel.

15. The side panel assembly according to claim 5, characterized in that, The side panel assembly also includes a crossbeam, and the joint assembly includes a crossbeam joint connected to the crossbeam, the crossbeam joint including the casting joint.

16. The side panel assembly according to claim 15, characterized in that, The casting joint of the beam connector is equipped with reinforcing ribs.

17. The side panel assembly according to claim 16, characterized in that, The casting joint includes a first side and a second side opposite to each other. The reinforcing rib is connected to the first side and extends in a direction away from the second side. The side assembly includes an inner plate, which is connected to the second side.

18. The side panel assembly according to claim 17, characterized in that, The second side is a plane.

19. The side panel assembly according to claim 15, characterized in that, The crossbeam joint is an integral structure.

20. A vehicle body structure component, characterized in that, Includes the side panel assembly as described in any one of claims 1-19.

21. A vehicle frame structure, characterized in that, Includes the side panel assembly as described in any one of claims 1-19 or the upper body structure component as described in claim 20.

22. A vehicle, characterized in that, It includes the side panel assembly as described in any one of claims 1-19, or the upper body structure assembly as described in claim 20, or the frame structure as described in claim 21.

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