Composite structure plastic automobile door and automobile

Abstract

The invention belongs to the field of automobiles, and particularly relates to a composite structure plastic automobile door which comprises an outer plate (1) and an inner plate (6), a reinforcing framework (4) is arranged between the outer plate (1) and the inner plate (6), the outer plate (1), the reinforcing framework (4) and the inner plate (6) are bonded with one another, and the invention further relates to an automobile provided with the composite structure plastic automobile door. Compared with the prior art, the interior trim panel is integrated into the inner plate, the structure of the automobile door is simplified, the automobile door which is high in automobile door assembly light weight degree, simple in process and convenient to install and overhaul is obtained, meanwhile, the inner plate and the outer plate are connected through the reinforcing framework, and the reinforcing framework is made of a composite material with higher rigidity to be arranged on the inner plate; meanwhile, the problem that thermal deformation of the inner plate and the outer plate of the automobile door is inconsistent due to high temperature and low temperature is solved, so that appearance matching of the automobile door is better guaranteed, and it is guaranteed that the automobile door gap and the surface difference meet the requirements.

Description

Technical Field

[0001] This invention belongs to the automotive field, specifically relating to a composite structure plastic car door and a car. Background Technology

[0002] Current composite material door panels are typically made of plastic, reinforced with steel or aluminum alloy frames. The interior panels are attached to the door via snap-fit ​​connections. While this satisfies the door's function and appearance, to ensure performance, the door structure is relatively complex, with thick inner and outer panels, numerous parts, and complex manufacturing processes. This results in low lightweighting of the door assembly and long mold processing cycles. Furthermore, the inconsistent materials of the inner and outer panels lead to differences in deformation due to thermal deformation, causing poor appearance matching between the door and surrounding parts when temperatures change. Additionally, due to limitations in the base material of the outer panel, PP material itself has a low Young's modulus and is prone to thermal deformation, resulting in insufficient door stiffness, weak dent resistance, and poor appearance. These issues contribute to insufficient lightweighting, low production efficiency, and short driving range in automobiles.

[0003] Patent CN105539095A discloses a lightweight car door, including an inner door panel, an outer door panel, exterior trim parts, and interior trim parts. The inner and outer door panels are metal frames, while the exterior trim parts and interior trim parts are plastic panels, which are produced by injection molding. However, this invention uses a metal frame as the main frame, and the overall weight of the car door cannot be reduced by using only plastic interior trim panels. Furthermore, the interior trim panels are not integrated with the car door.

[0004] Therefore, there is an urgent need for a composite structure car door to solve the problems of existing composite material car doors, such as the inability to integrate interior panels, low lightweighting, large number of parts, complex structure, complex processing technology, and poor appearance matching. Summary of the Invention

[0005] The purpose of this invention is to provide a composite structure plastic car door and a car to solve at least one of the above-mentioned problems, thereby addressing the issues of low lightweighting, poor door strength, and complex manufacturing processes caused by the inability to integrate interior panels in existing composite material car doors. This invention fulfills the requirements of car doors for lightweighting, dent resistance of outer panels, outer panel stiffness, matching of gap surface differences, and mass production, thus satisfying the lightweighting requirements of automobiles.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] One of the technical solutions of the present invention is to provide a composite structure plastic car door, including an outer panel and an inner panel, wherein a reinforcing frame is provided between the outer panel and the inner panel, and the outer panel, the reinforcing frame and the inner panel are bonded to each other.

[0008] Furthermore, the reinforcing frame includes multiple spaced-apart bone reinforcing plates and a horizontal reinforcing structure between adjacent bone reinforcing plates.

[0009] Furthermore, the outer panel is bonded to the reinforcing frame and the inner panel using structural adhesive I, and the reinforcing frame is bonded to the inner panel using structural adhesive II.

[0010] By using structural adhesive to bond the reinforcing frame, outer panel, and inner panel, a sealing effect is achieved while also providing an aesthetically pleasing result.

[0011] The horizontal reinforcement structure is multi-layered and arranged at intervals along the height direction of the bone reinforcement plate.

[0012] The outer panel and inner panel are connected by a reinforced frame, dividing the door into multiple cavity structures. This increases the moment of inertia of the door section, significantly improving the rigidity of the outer panel and the overall strength of the door. It also improves the problem of inconsistent thermal deformation of the inner and outer panels caused by high and low temperatures, thus better ensuring the appearance matching of the door and ensuring that the gaps and surface differences between the door meet the requirements.

[0013] Furthermore, the material of the reinforcing skeleton includes any one of glass fiber reinforced PP composite material, glass fiber reinforced PC composite material, carbon fiber reinforced PP composite material, carbon fiber reinforced PC composite material, carbon-glass hybrid fiber composite material, metal material and SMC material.

[0014] Furthermore, the inner side of the inner panel has interior trim integration, which helps to reduce the overall weight of the door, reduce the number of parts, improve the door's aesthetics, and shorten the door's manufacturing cycle.

[0015] Furthermore, the structural adhesive I and structural adhesive II are selected from one or more of structural reinforcing adhesives, shock-absorbing adhesives, expanding adhesives, and 3M adhesives, and the use of different adhesive types meets the requirements of the car door for sealing, rigidity, strength, etc.

[0016] Furthermore, the structural adhesive II bonds the reinforcing skeleton to the inner panel to form the inner panel assembly.

[0017] Furthermore, the material of the inner panel includes any one of glass fiber reinforced PP composite material, glass fiber reinforced PC composite material, carbon fiber reinforced PP composite material, carbon fiber reinforced PC composite material, carbon-glass hybrid fiber composite material, and SMC material.

[0018] Furthermore, the outer panel is a plastic outer panel made of composite materials, including either PP mixed with talc or PC-ABS. Outer panels made of this material offer the advantage of diverse styling not found in traditional sheet metal stamped doors: they can achieve complex shapes and integrate optical and electrical components.

[0019] Traditional metal outer panels are mostly stamped parts, which cannot achieve complex installation structures and have poor wave and light transmission; plastic outer panels can achieve the installation structure of electrical components through injection molding; optical and electrical components are integrated through installation methods such as snap-fit ​​and screw-fit.

[0020] The second technical solution of the present invention provides a method for constructing a composite structure plastic car door, comprising the following steps:

[0021] S1: An inner panel assembly is formed by bonding a reinforcing frame and an inner panel together with structural adhesive II.

[0022] S2: Provide a structural adhesive I to bond the outer panel to the inner panel assembly.

[0023] Furthermore, the bonding method can be manual bonding or bonding using a membrane positioning method.

[0024] The third technical solution of the present invention is to provide a car equipped with the aforementioned composite structure plastic door.

[0025] Compared with the prior art, the present invention has the following advantages:

[0026] 1. By reinforcing the inner panel with a skeleton to connect the inner and outer panels, the door is divided into multiple cavity structures, increasing the moment of inertia of the door section and significantly improving the rigidity of the outer panel and the overall rigidity of the door. At the same time, it improves the problem of inconsistent thermal deformation of the inner and outer panels caused by high and low temperatures, thus better ensuring the appearance matching of the door and ensuring that the gaps and surface differences of the door meet the requirements, satisfying the needs of automobile doors for dent resistance, rigidity, and gap surface difference matching of the outer panel.

[0027] 2. This invention integrates the interior trim onto the inner panel and uses structural adhesive to bond the various parts together, reducing the overall weight of the door, improving its aesthetics, and shortening the manufacturing cycle. By addressing the door's weight, it meets the requirements for lightweighting automobiles and helps improve the vehicle's range.

[0028] 3. The outer panel is made of plastic injection molding, which has the advantage of diverse shapes that traditional sheet metal stamping doors do not have. It can realize some complex shape features and can integrate optical and electrical components to meet the development needs of diversified, intelligent and modular automotive door shapes.

[0029] 4. The interior panel integrated composite structure plastic car door of the present invention has a simple structure, few parts, simple process, convenient mold processing, and is easy to manufacture, install and maintain.

[0030] 5. Compared with the prior art, the present invention simplifies the structure of the car door by integrating the interior trim panel into the inner panel, resulting in a car door assembly with high lightweighting, simple manufacturing process, and easy installation and maintenance. At the same time, a reinforcing frame is used to connect the inner panel and the outer panel, and a reinforcing frame made of a more rigid composite material is used to make the inner panel, which significantly improves the rigidity of the outer panel and the overall rigidity of the car door. It also improves the problem of inconsistent thermal deformation of the inner and outer panels of the car door caused by high and low temperatures, thereby better ensuring the appearance matching of the car door and ensuring that the gaps and surface differences of the car door meet the requirements. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of the plastic car door assembly of the present invention;

[0032] Figure 2 This is an exploded view of the plastic door assembly of the present invention;

[0033] Figure 3 This is an exploded view of the plastic inner panel assembly of the present invention.

[0034] In the diagram: 1-Outer panel; 2-Structural adhesive I; 3-Inner panel assembly; 4-Reinforcing frame; 5-Structural adhesive II; 6-Inner panel. Detailed Implementation

[0035] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0036] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0037] The purpose of this invention is to solve the problems existing in the prior art and to propose a novel composite structure plastic car door system solution. This solution provides a door that can meet the needs of future automobiles, especially new energy electric vehicles, to meet the requirements of lightweighting, improve the driving range of electric vehicles, and meet the important development directions of diversified styling, intelligence, and modularization. Moreover, the solution and concept of this invention are applicable to composite material car doors and hoods.

[0038] Compared with existing technologies, this invention simplifies the structure of the car door by integrating the interior trim panel into the inner panel, resulting in a car door assembly with high lightweighting, simple manufacturing process, and easy installation and maintenance. At the same time, a reinforcing frame connects the inner and outer panels, and the reinforcing frame made of a more rigid composite material is used in the inner panel, which significantly improves the rigidity of the outer panel and the overall rigidity of the car door. It also improves the problem of inconsistent thermal deformation of the inner and outer panels of the car door caused by high and low temperatures, thereby better ensuring the appearance matching of the car door and ensuring that the gaps and surface differences of the door meet the requirements.

[0039] The following is in accordance with... Figures 1-3 As shown, the specific embodiments of the present invention will be further described in detail through the description of the examples. This includes descriptions of the assembly structure of the plastic door system, exploded views of the system assembly, and schematic diagrams of the assembly and installation structure strategy.

[0040] like Figure 1 The diagram shown is a structural schematic of the plastic door assembly of the present invention. The overall structure of the invention is displayed through a transparent outer panel; the various details of the invention are described below.

[0041] The present invention provides a composite structure plastic car door comprising an outer panel 1 and an inner panel 6, wherein a reinforcing frame 4 is provided between the outer panel 1 and the inner panel 6, and the outer panel 1, the reinforcing frame 4 and the inner panel 6 are bonded together.

[0042] The outer panel 1 and the reinforcing frame 4, as well as the outer panel 1 and the inner panel 6, are bonded together by structural adhesive I2, and the reinforcing frame 4 and the inner panel 6 are bonded together by structural adhesive II5.

[0043] like Figure 2 The figure shown is an exploded view of the structure of the plastic door assembly of the present invention. Figure 2 The main components of the interior panel integrated composite structure plastic car door are shown in the image. They include the outer panel 1, structural adhesive 12, and inner panel assembly 3, which are connected together to form the novel composite structure plastic car door reinforcement frame of the present invention. This frame is the main load-bearing structure of the car door of the present invention.

[0044] like Figure 3 The figure shown is an exploded view of the structure of the plastic inner panel assembly 3 of the present invention. Figure 3 The main components of the composite structure plastic inner panel assembly 3 are shown in the image. They include a reinforcing skeleton 4, structural adhesive II5, and an inner panel 6. The reinforcing skeleton 4 and the inner panel 6 are bonded together by structural adhesive II5 to form the inner panel assembly 3.

[0045] The reinforcing frame 4 includes multiple spaced-apart bone reinforcing plates and a horizontal reinforcing structure between adjacent bone reinforcing plates.

[0046] The horizontal reinforcement structure is multi-layered and arranged at intervals along the height direction of the bone reinforcement plate.

[0047] By using structural adhesive to bond the reinforcing frame, outer panel, and inner panel, a sealing effect is achieved while also providing an aesthetically pleasing result.

[0048] The outer panel and inner panel are connected by a reinforced frame, dividing the door into multiple cavity structures. This increases the moment of inertia of the door section, significantly improving the rigidity of the outer panel and the overall strength of the door. It also improves the problem of inconsistent thermal deformation of the inner and outer panels caused by high and low temperatures, thus better ensuring the appearance matching of the door and ensuring that the gaps and surface differences between the door meet the requirements.

[0049] Combination Figure 2 , Figure 3 As shown, the materials of each part of the composite structure plastic car door of the present invention are: the outer panel 1 is a plastic outer panel made of composite material, which includes either PP mixed with talc material or PC-ABS material;

[0050] The reinforcing skeleton 4 is made of any one of the following materials: glass fiber reinforced PP composite material, glass fiber reinforced PC composite material, carbon fiber reinforced PP composite material, carbon fiber reinforced PC composite material, carbon-glass hybrid fiber composite material, metal material, and SMC material.

[0051] The material of the inner panel 6 includes any one of glass fiber reinforced PP composite material, glass fiber reinforced PC composite material, carbon fiber reinforced PP composite material, carbon fiber reinforced PC composite material, carbon-glass hybrid fiber composite material, and SMC material.

[0052] The outer panel 1 is a plastic outer panel made of composite materials, specifically PP mixed with talc powder and PC-ABS materials, etc., which are injection molded plastic outer panels. Plastic outer panels made of this material have the advantage of diverse shapes that traditional sheet metal stamping doors do not have: they can achieve some complex shape features and can integrate optical and electrical components, etc.

[0053] Structural Adhesive I2 and Structural Adhesive II5 are selected from one or more of structural reinforcing adhesives, shock-absorbing adhesives, expanding adhesives, and 3M adhesives. By using different types of adhesives, they meet the requirements of car doors for sealing, rigidity, strength, etc.

[0054] The inner panel 6 has interior trim integration, that is, the interior trim integration of the composite structure plastic car door of the present invention helps to reduce the overall weight of the car door, reduce the number of parts, improve the aesthetics of the car door, and shorten the manufacturing cycle of the car door.

[0055] The inner panel assembly 3, including the reinforcing frame 4 and the inner panel 6, is injection molded from glass fiber or carbon fiber reinforced composite materials, which significantly improves the rigidity of the outer panel and the overall rigidity of the door.

[0056] The bonding methods for structural adhesive I2 and structural adhesive II5 include manual bonding or bonding of the membrane positioning method.

[0057] The construction method of a composite structure plastic car door provided by the above preferred embodiment is described below:

[0058] First, the injection-molded inner panel reinforcing skeleton 4 and the inner panel 6 are manually bonded together with structural adhesive II5 to form the inner panel assembly 3.

[0059] Then, the inner panel assembly 3 is placed in a mold; the injection-molded outer panel 1 is placed in another mold, structural adhesive I2 is applied to the corresponding position of the outer panel 1, and then the adhesive-coated outer panel 1 is bonded to the inner panel assembly 3 through the mold, thus forming the plastic door assembly of the present invention.

[0060] A car equipped with the composite structure plastic door according to the above preferred embodiment.

[0061] The above description of the embodiments is provided to enable those skilled in the art to understand and use the invention. It will be apparent to those skilled in the art that various modifications can be made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present invention is not limited to the above embodiments, and any improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the invention should be within the protection scope of the present invention.

Claims

1. A composite structure plastic car door, comprising an outer panel (1) and an inner panel (6), characterized in that, A reinforcing frame (4) is provided between the outer plate (1) and the inner plate (6), and the outer plate (1), the reinforcing frame (4) and the inner plate (6) are bonded to each other.

2. The composite structure plastic car door according to claim 1, characterized in that, The reinforcing frame (4) includes multiple spaced-apart bone reinforcing plates and a horizontal reinforcing structure connecting adjacent bone reinforcing plates.

3. A composite structure plastic car door according to claim 2, characterized in that, The horizontal reinforcement structure is multi-layered and arranged at intervals along the height direction of the bone reinforcement plate.

4. A composite structure plastic car door according to claim 1, characterized in that, The reinforcing skeleton (4) is made of any one of the following materials: glass fiber reinforced PP composite material, glass fiber reinforced PC composite material, carbon fiber reinforced PP composite material, carbon fiber reinforced PC composite material, carbon-glass hybrid fiber composite material, metal material and SMC material.

5. A composite structure plastic car door according to claim 1, characterized in that, The inner panel (6) has interior trim integrated on its inner side.

6. A composite structure plastic car door according to claim 1, characterized in that, The outer panel (1) and the reinforcing frame (4) and the outer panel (1) and the inner panel (6) are bonded together by structural adhesive I (2), and the reinforcing frame (4) and the inner panel (6) are bonded together by structural adhesive II (5).

7. A composite structure plastic car door according to claim 6, characterized in that, The structural adhesive I (2) and structural adhesive II (5) are selected from one or more of structural reinforcing adhesive, shock-resistant adhesive, expanding adhesive and 3M adhesive.

8. A composite structure plastic car door according to claim 1, characterized in that, The inner panel (6) material includes any one of glass fiber reinforced PP composite material, glass fiber reinforced PC composite material, carbon fiber reinforced PP composite material, carbon fiber reinforced PC composite material, carbon glass hybrid fiber composite material and SMC material.

9. A composite structure plastic car door according to claim 1, characterized in that, The outer panel (1) is a plastic outer panel made of composite material, which includes either PP mixed with talc material or PC-ABS material.

10. A car equipped with a composite structure plastic door as described in any one of claims 1-9.

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